Curing Agent for Low Temperature Cure Applications

ABSTRACT

The present invention provides Mannich base derivatives of N,N′-dimethyl secondary diamine polymers including Mannich base derivatives of methylamine-terminated poly-(N-methylazetidine) and Mannich base derivatives of methylamine-terminated poly-(N-methylazacycloheptane). Amine curing agent compositions and amine-epoxy compositions containing Mannich base derivatives of N,N′-dimethyl secondary diamine polymers are also disclosed.

BACKGROUND OF THE INVENTION

The present invention relates generally to Mannich base derivatives ofN,N′-dimethyl secondary diamine polymeric compounds, amine andamine-epoxy compositions employing these materials, and methods ofmaking epoxy resin compositions.

Epoxy resins which are cured, hardened, or crosslinked withmultifunctional amines, i.e., amine compounds having three or moreactive amine hydrogens, are well known in the industry. These materialsare widely used in applications such as coatings, adhesives, composites,and civil engineering applications such as formulations for flooring. Incoating applications, amine-cured epoxy formulations generally can becured at room temperature to yield films with high mechanical strength,good water, chemical, and corrosion resistance, and excellent adhesionproperties, particularly to metallic substrates. Thus, they are oftenemployed as primers and topcoats for large structures such as ships,bridges, and industrial plants and equipment.

Before regulations placing limits on the volatile organic compound (VOC)content of amine-epoxy coatings, formulations were often based on solidepoxy resins. These resins are solid at room temperature. Coatings usingsolid epoxy resins usually dried very quickly, since only solventevaporation, not chemical cure, was required for the coating to reach adry-to-touch state.

Due to the VOC regulations, epoxy resins that are liquids at roomtemperature have replaced solid epoxy resins in many applications. Thistransition has resulted in several problems, for example, in coatingapplications. Amine-epoxy compositions based upon liquid epoxy resinstend to cure much more slowly than a comparable solid epoxy resinformulation, and this problem becomes more severe at lower temperatures.Shipyards, for example, often reside in locations with cold winters, andpaint must be applied when temperatures are about 5° C. or colder.Certain amine-epoxy coating formulations cure very slowly at thesetemperatures, often requiring at least 24 hours, and in some cases muchmore than 24 hours, to reach the “walk-on” dry state required so thatpainters can apply a second or third coat, if required. In thelaboratory, the “walk-on” dry state is often estimated by thethumb-twist test method. Slow drying times can dramatically impact ashipyard's productivity. Thus, fast cure speed at below room temperatureis a desirable property in many applications.

It is also beneficial to limit the volatility of the amine component inthe amine-epoxy formulation. In addition to meeting VOC regulations,reducing volatility can reduce worker exposure and safety concerns.

Amine-epoxy coating formulations based on a liquid epoxy resin, asopposed to a solid epoxy resin, can also be less flexible than requiredfor certain applications. For example, in ships employing modern doublehull construction, the steel used in the two hulls that form the ballasttank is a thinner gauge than used in single hull ships. As a result ofthe thinner gauge, the steel flexes more which can lead to a stresscrack failure of the coating, especially around welded joints. This inturn can lead to corrosion, which can be expensive to repair and canaffect the ship's integrity. Further, in the rail car industry, thereare also problems due to lack of coating flexibility at the weld seams.Additionally, coatings in many other applications require greaterflexibility, for example, to achieve a desired impact resistance for agiven application, or to post-form a metal after painting. In theend-use application, the amount of stress or deformation that thematerial undergoes, as well as the rate of deformation, are importantfactors for determining the flexibility required and thus thesuitability of a particular amine-epoxy composition or formulation. Incivil engineering applications, for example, those involving concreteand other cementitious materials, amine-epoxy materials capable ofwithstanding greater expansion and contraction stresses, and capable ofmeeting crack bridging requirements, are also of interest.

Many epoxy coatings are over-coated with a second or third coating. Theadditional coatings are not limited to epoxy-based systems and caninclude other chemical coating systems (e.g., polyurethanes) in order toprovide particular end-use properties, such as corrosion resistance,weatherability, etc. Intercoat adhesion in formulations based on liquidepoxy resins typically is less than comparable solid epoxy resinformulations, often leading to intercoat adhesion failures. Whenadequate intercoat adhesion for a liquid epoxy system is obtained,re-coating often must occur within a limited time frame if intercoatadhesion failures are to be avoided. This time is often referred to asthe re-coat window.

Many amine-epoxy coatings suffer from problems referred to in theindustry as blush, carbamation, and exudate. These problems, in part,are due to the incompatibility of the amine curing agent and the epoxyresin, which causes phase separation and results in amine migration tothe coating surface. In primary amines, the migratory amine can reactwith CO₂ present in the air, resulting in carbamation. Whether in theform of carbamation or the greasy surface layer referred to as exudateor blush, these surface defects detract from the appearance of thecoating, and can lead to intercoat adhesion failures if the film isre-coated. These problems are generally worse for coatings applied andcured at colder temperatures, where amine-epoxy compatibility isreduced.

Certain Mannich bases can be used in amine-epoxy formulations becausethey often exhibit fast cure rates at low temperatures, but suchmaterials are not without drawbacks. For example, amine-epoxy coatingsemploying certain Mannich bases often suffer from blush, carbamation,and exudate, as well as poor coating flexibility. In addition, dependingupon the process used to synthesize the Mannich base compound,unacceptable amounts of residual phenol may remain. Phenol is a toxicchemical, and its presence at levels greater than 1% in a chemicalmixture can require special disposal techniques, special labeling, andthe use of personal protective equipment to minimize worker exposure.

There are several broad classes of multifunctional amine curing agentsthat are employed in the amine-epoxy coating industry, includingpolyamides, Mannich bases (including phenalkamines), and amine adducts.None of these known products addresses the needs or solves the problemsnoted above. Accordingly, it is to this end that the present inventionis directed.

BRIEF SUMMARY OF THE INVENTION

The present invention discloses novel Mannich base derivativecompositions comprising Mannich base compounds, and methods of makingthese new compositions. These Mannich base derivative compositions canbe used, for example, as amine-based curing agents in amine-epoxycompositions.

In one aspect of the present invention, the Mannich base derivativecomposition comprises a Mannich base reaction product of:

(a) at least one aldehyde compound;

(b) at least one phenol compound; and

(c) at least one N,N′-dimethyl secondary diamine polymer having anumber-average molecular weight (M_(n)) from about 140 to about 1000.

In another aspect, the Mannich base derivative composition comprises areaction product of:

(a) at least one di-substituted or tri-substituted Mannich basecompound; and

(b) at least one N,N′-dimethyl secondary diamine polymer having a M_(n)from about 140 to about 1000.

In yet another aspect, the Mannich base derivative composition comprisesamine compounds having the following formula:

wherein:

m is 1, 2, or 3;

R is a hydrogen atom or a C₁-C₁₈ linear or branched alkyl or alkenylgroup;

each R′ independently is a hydrogen atom or a moiety having the formula:

wherein:

-   -   R is defined as above;    -   t is 0, 1, or 2;    -   each R″ independently is a hydrogen atom or a moiety having the        formula;

wherein:

-   -   R is defined as above;    -   u is 0, 1, or 2; and

each X independently is a polyoxyalkylene moiety or a moiety having theformula:

wherein:

R₁ is a C₂-C₈ linear or branched alkanediyl; and

n is an integer in a range from 0 to 50, inclusive.

Amine curing agent compositions are provided in other aspects of thepresent invention. Such compositions can be used to cure, harden, orcrosslink an epoxy resin. An amine curing agent composition can comprise(i) any one of the three aforementioned Mannich base derivativecompositions, provided immediately above; and (ii) at least onemultifunctional amine having 3 or more active amine hydrogens.

In another aspect, the present invention is directed to amine-epoxycompositions comprising (a) a Mannich base derivative composition and,optionally, at least one multifunctional amine having 3 or more activeamine hydrogens; and (b) an epoxy component comprising at least onemultifunctional epoxy resin. Compositions obtained by curing theamine-epoxy compositions of the present invention, as well as articlesof manufacture comprising these compositions, are also contemplated bythe present invention. Such articles can include, but are not limitingto, a coating, an adhesive, a construction product, a flooring product,a composite product, and the like.

Amine-epoxy compositions of the present invention can be used to producecoatings with improved “walk-on” dry times, rapid hardness development,good gloss and surface appearance, and/or outstanding impact resistanceand flexibility as compared to conventional amine-epoxy coatings.

DEFINITIONS

The following definitions and abbreviations are provided in order to aidthose skilled in the art in understanding the detailed description ofthe present invention.

-   -   ANEW—amine hydrogen equivalent weight.    -   BA—benzyl alcohol, commercially available from Fisher Scientific        UK Ltd.    -   CX-105—Sunmide® CX-105, commercially available from Air Products        and Chemicals, Inc., phenalkamine, ANEW=142.    -   DGEBA—diglycidyl ether of bisphenol-A.    -   EEW—epoxy equivalent weight.    -   K54—Ancamine® K54, commercially available from Air Products and        Chemicals, Inc., tris-(dimethylaminomethyl)phenol.    -   M_(n)—number-average molecular weight.    -   MPCA—also abbreviated as MBPCAA. MPCA is a mixture of methylene        bridged poly(cyclohexyl-aromatic)amines that fits within the        class of multifunctional amines. Ancamine® 2168, commercially        available from Air Products and Chemicals, Inc., is a MPCA with        an AHEW of 57 and is the grade utilized in the examples.    -   NC541LV—Cardolite® NC541 LV, commercially available from        Cardolite Corporation, low viscosity phenalkamine, AHEW=125.    -   PHR—parts per hundred weight resin.

DETAILED DESCRIPTION OF THE INVENTION Amine and Amine-Epoxy Compositions

The present invention discloses novel Mannich base derivativecompositions comprising Mannich base compounds, and methods of makingthese new compositions. According to one aspect of this invention, theMannich base derivative composition comprises a Mannich base reactionproduct of:

(a) at least one aldehyde compound;

(b) at least one phenol compound; and

(c) at least one N,N′-dimethyl secondary diamine polymer having anumber-average molecular weight (M_(n)) from about 140 to about 1000.

In another aspect, the Mannich base derivative composition comprises areaction product of:

(a) at least one di-substituted or tri-substituted Mannich basecompound; and

(b) at least one N,N′-dimethyl secondary diamine polymer having a M_(n)from about 140 to about 1000.

In yet another aspect, the Mannich base derivative composition comprisesamine compounds having the following formula:

wherein:

m is 1, 2, or 3;

R is a hydrogen atom or a C₁-C₁₈ linear or branched alkyl or alkenylgroup;

each R′ independently is a hydrogen atom or a moiety having the formula:

wherein:

-   -   R is defined as above;    -   t is 0, 1, or 2;    -   each R″ independently is a hydrogen atom or a moiety having the        formula;

wherein:

-   -   R is defined as above;    -   u is 0, 1, or 2; and

each X independently is a polyoxyalkylene moiety or a moiety having theformula:

wherein:

R₁ is a C₂-C₈ linear or branched alkanediyl; and

n is an integer in a range from 0 to 50, inclusive.

Amine curing agent compositions are provided in other aspects of thepresent invention. For example, an amine curing agent composition can beused to cure, harden, or crosslink an epoxy resin. An amine curing agentcomposition can comprise (i) any one of the three aforementioned Mannichbase derivative compositions, provided immediately above; and (ii) atleast one multifunctional amine having 3 or more active amine hydrogens.

In another aspect of the present invention, the amine curing agentcomposition can comprise from 1% to 99% of a Mannich base derivativecomposition. In another aspect, the Mannich base derivative compositioncan be used in amounts between about 10% and about 90% of the totalamine curing agent composition. These percentages are weight percentagesbased upon the weight of the total amine curing agent composition. Thatis, the presence of additional components is not included in the weightpercent calculation. For example, as used in the practice ofmanufacturing coatings, the amine curing agent composition can beprovided in a diluent or solvent such as benzyl alcohol. Thus, when apercentage by weight of an amine component or a composition of thepresent invention is discussed, the quantity will exclude the effect ofany diluents or other additives, unless stated otherwise. As an example,if 65 parts by weight of a Mannich base derivative composition of thepresent invention and 35 parts by weight of a multifunctional amine areused in conjunction with 40 parts by weight benzyl alcohol and anadditive (e.g., a filler) in a given application, the weight percent ofthe Mannich base derivative composition is 65% based on the weight ofthe total amine curing agent composition. The presence of additionalmaterials does not affect the determination of the percentage of theMannich base derivative composition in relation to the total weight ofthe amine curing agent composition.

Another curing agent composition in accordance with the presentinvention comprises (i) about 90% to about 10% by weight, based on totalamine curing agent composition, of a Mannich base derivativecomposition; and (ii) about 10% to about 90% by weight, based on totalamine curing agent composition, of at least one multifunctional aminehaving 3 or more active amine hydrogens. In a further aspect, the atleast one multifunctional amine having 3 or more active amine hydrogensalso has 6 or more carbon atoms.

The present invention also contemplates an amine curing agentcomposition in which about 80% to about 20% by weight of the total aminecuring agent composition is the Mannich base derivative composition. Inyet another aspect, about 75% to about 25% by weight of the total aminecuring agent composition is the Mannich base derivative composition.Again, in these contexts, the Mannich base derivative composition can beany of the three aforementioned Mannich base derivative compositionsprovided above.

The relative amount of the Mannich base derivative composition versusthat of the multifunctional amine can vary depending upon, for example,the end-use article, its desired properties, and the fabrication methodand conditions used to produce the end-use article. For instance, inamine-epoxy coating applications, incorporating more of the Mannich basederivative composition relative to the amount of the multifunctionalamine generally results in coatings which have greater flexibility, abroader re-coat window, and that cure faster and/or can be cured atlower temperatures. Conversely, incorporating relatively moremultifunctional amine generally results in coatings with improvedchemical resistance and often higher ultimate hardness.

In accordance with another aspect of the present invention, anamine-epoxy composition is provided. For example, an amine-epoxycomposition can comprise:

(a) a Mannich base derivative composition; and

(b) an epoxy component comprising at least one multifunctional epoxyresin.

Yet, in another aspect of the present invention, an amine-epoxycomposition is provided, which comprises:

(a) an amine curing agent composition; and

(b) an epoxy component comprising at least one multifunctional epoxyresin.

In this aspect, the amine curing agent composition can comprise (i) anyone of the three aforementioned Mannich base derivative compositions;and (ii) at least one multifunctional amine having 3 or more activeamine hydrogens.

In a further aspect, the present invention contemplates a method forcuring the amine-epoxy compositions indicated above. For example, theamine-epoxy composition can be cured at a temperature of less than orequal to about 23° C. In another aspect, the amine-epoxy composition iscured at a temperature of less than or equal to about 5° C. Theamine-epoxy compositions of the present invention offer improved curerates at temperatures at or below room temperature, includingtemperatures less than or equal to about 5° C., as compared toconventional amine-epoxy compositions.

The amine-epoxy compositions of the present invention comprise (a) aMannich base derivative composition and, optionally, at least onemultifunctional amine having 3 or more active amine hydrogens; and (b)an epoxy component comprising at least one multifunctional epoxy resin.Compositions obtained by curing the amine-epoxy compositions of thepresent invention, as well as articles of manufacture comprising thesecompositions, are also contemplated by the present invention. Sucharticles can include, but are not limiting to, a coating, an adhesive, aconstruction product, a flooring product, a composite product, and thelike. For example, the article can be a coating which is applied to ametal or cementitious substrate. Additional components or additives canbe used together with the compositions of the present invention toproduce various articles of manufacture.

The present invention also provides methods of making an epoxy resincomposition. One such method comprises:

(a) forming an amine component comprising a Mannich base derivativecomposition and optionally at least one multifunctional amine having 3or more active amine hydrogens, and(b) contacting the amine component with at least one multifunctionalepoxy resin at a stoichiometric ratio of epoxy groups in themultifunctional epoxy resin to amine hydrogens in the amine componentranging from about 1.5:1 to about 1:1.5.

In accordance with the amine-epoxy compositions and methods of making anepoxy composition disclosed herein, the stoichiometric ratio of epoxygroups in the epoxy component to amine hydrogens in the amine componentor composition ranges from about 1.5:1 to about 1:1.5. Yet, in anotheraspect, the stoichiometric ratio of epoxy groups in the epoxy componentto amine hydrogens in the amine component or composition ranges fromabout 1.3:1 to about 1:1.3. These stoichiometric ratios are based on thetotal quantities of the respective amine and epoxy components. Forexample, if the amine component contains 65 parts by weight of a Mannichbase derivative composition and 35 parts by weight of a multifunctionalamine, the total amount of amine hydrogens from both the Mannich basederivative composition and the multifunctional amine are used todetermine the stoichiometric ratio.

Additionally, it can be beneficial in the compositions of the presentinvention for all of the possible components to be liquids at roomtemperature. That is, the Mannich base derivative composition, the atleast one multifunctional amine compound, and the at least onemultifunctional epoxy resin compound can all be liquids at roomtemperature. In this disclosure, room temperature, or ambienttemperature, is approximately 23° C.

Applicants disclose several types of ranges in the present invention.These include, but are not limited to, a range of weight percentages, arange of temperatures, a range of number of atoms, a range of molecularweights, a range of amine hydrogen equivalent weights, a range of aminevalues, a range of integers, and a range of stoichiometric ratios. WhenApplicants disclose or claim a range of any type, Applicants' intent isto disclose or claim individually each possible number that such a rangecould reasonably encompass, as well as any sub-ranges and combinationsof sub-ranges encompassed therein. For example, when the Applicantsdisclose or claim a chemical moiety having a certain number of carbonatoms, Applicants' intent is to disclose or claim individually everypossible number that such a range could encompass, consistent with thedisclosure herein. For example, the disclosure that “R” can be a C₁ toC₁₈ linear or branched alkyl or alkenyl group, or in alternativelanguage having from 1 to 18 carbon atoms, as used herein, refers to a“R” group that can be selected independently from an alkyl or alkenylgroup having 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,or 18 carbon atoms, as well as any range between these two numbers (forexample, a C₁ to C₁₀ alkyl or alkenyl group), and also including anycombination of ranges between these two numbers (for example, a C₂ to C₆and C₉ to C₁₅ alkyl or alkenyl group).

Similarly, another representative example follows for the amine value ofa Mannich base derivative composition in units of mg KOH/g. By adisclosure that the amine value is in a range from about 85 to about910, Applicants intend to recite that the amine value can be selectedfrom about 85, about 90, about 95, about 100, about 105, about 110,about 115, about 120, about 125, about 130, about 135, about 140, about145, about 150, about 160, about 170, about 180, about 190, about 200,about 210, about 220, about 230, about 240, about 250, about 260, about270, about 280, about 290, about 300, about 310, about 320, about 330,about 340, about 350, about 360, about 370, about 380, about 390, about400, about 410, about 420, about 430, about 440, about 450, about 460,about 470, about 480, about 490, about 500, about 510, about 520, about530, about 540, about 550, about 560, about 570, about 580, about 590,about 600, about 610, about 620, about 630, about 640, about 650, about660, about 670, about 680, about 690, about 700, about 710, about 720,about 730, about 740, about 750, about 760, about 770, about 780, about790, about 800, about 810, about 820, about 830, about 840, about 850,about 860, about 870, about 880, about 890, about 900, or about 910.Additionally, the amine value can be within any range from about 85 toabout 910 (for example, the amine value is in a range from about 400 toabout 900), and this includes any combination of ranges between about 85and about 910 (for example, the amine value is in a range from about 100to about 300, or from about 700 to about 880). Likewise, all otherranges disclosed herein should be interpreted in a manner similar tothese two examples.

Applicants reserve the right to proviso out or exclude any individualmembers of any such group, including any sub-ranges or combinations ofsub-ranges within the group, that can be claimed according to a range orin any similar manner, if for any reason Applicants choose to claim lessthan the full measure of the disclosure, for example, to account for areference that Applicants may be unaware of at the time of the filing ofthe application. Further, Applicants reserve the right to proviso out orexclude any individual substituents, analogs, compounds, ligands,structures, or groups thereof, or any members of a claimed group, if forany reason Applicants choose to claim less than the full measure of thedisclosure, for example, to account for a reference that Applicants maybe unaware of at the time of the filing of the application.

The term “contact product” is used herein to describe compositionswherein the components are contacted together in any order, in anymanner, and for any length of time. For example, the components can becontacted by blending or mixing. Further, contacting of any componentcan occur in the presence or absence of any other component of thecompositions or formulations described herein. Combining additionalmaterials or components can be done by any method known to one of skillin the art. Further, the term “contact product” includes mixtures,blends, solutions, slurries, reaction products, and the like, orcombinations thereof. Although “contact product” can encompass reactionproducts of two or more components, it is not required for therespective components to react with one another.

While compositions and methods are described in terms of “comprising”various components or steps, the compositions and methods can also“consist essentially of” or “consist of” the various components orsteps.

Mannich Base Derivative Compositions

Generally, the Mannich base derivative compositions of the presentinvention are polymeric, non-gelled compositions comprising aminecompounds. One such composition comprises amine compounds illustrated bythe following formula:

wherein:

m is 1, 2, or 3;

R is a hydrogen atom or a C₁-C₁₈ linear or branched alkyl or alkenylgroup;

each R′ independently is a hydrogen atom or a moiety having the formula:

wherein:

-   -   R is defined as above;    -   t is 0, 1, or 2;    -   each R″ independently is a hydrogen atom or a moiety having the        formula;

wherein:

-   -   R is defined as above;    -   u is 0, 1, or 2; and

each X independently is a polyoxyalkylene moiety or a moiety having theformula:

wherein:

R₁ is a C₂-C₈ linear or branched alkanediyl; and

n is an integer in a range from 0 to 50, inclusive.

Polymeric Mannich base derivative compositions encompassed by formula(I-A) having an amine hydrogen equivalent weight (AHEW) from about 98 toabout 2100 are within the scope of the present invention. In anotheraspect, the composition has an AHEW in the range from about 100 to about1700, or from about 105 to about 1350. In yet another aspect, the AHEWis in a range from about 105 to about 1000, from about 105 to about 750,or from about 105 to about 500. For example, the AHEW of the Mannichbase derivative composition can be in a range from about 115 to about300.

The amine value of the Mannich base derivative composition encompassedby formula (I-A) typically falls within a range from about 85 to about910 mg KOH/g. The amine value of this composition can be within a rangefrom about 100 to about 910, from about 130 to about 900, or from about200 to about 890, in other aspects of this invention. For example, theamine value can be in a range from about 300 to about 890. In anotheraspect, the amine value is in a range from about 400 to about 900, fromabout 500 to about 900, or from about 600 to about 900. In a differentaspect, the amine value of the Mannich base derivative composition is ina range from about 700 to about 880.

Formula (I-A) above, as well as formulas (I-B), (I-C), and (II), are notdesigned to show stereochemistry or isomeric positioning of thedifferent moieties (e.g., these formulas are not intended to show cis ortrans isomers), although such compounds are contemplated and encompassedby these formulas.

The integer m in formula (I-A) is 1, 2, or 3, while R can be a hydrogenatom or a C₁-C₁₈ linear or branched alkyl or alkenyl group. Unlessotherwise specified, alkyl and alkenyl groups described herein areintended to include all structural isomers, linear or branched, of agiven moiety; for example, all enantiomers and all diastereomers areincluded within this definition. As an example, unless otherwisespecified, the term propyl is meant to include n-propyl and iso-propyl,while the term butyl is meant to include n-butyl, iso-butyl, t-butyl,sec-butyl, and so forth. For instance, non-limiting examples of octylisomers include 2-ethyl hexyl and neooctyl. Suitable examples of alkylgroups which can be employed in the present invention include, but arenot limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl,octyl, nonyl, decyl, docedyl, and the like. Other alkyl groups such as,for example, a C₁₄ alkyl, a C₁₅ alkyl, a C₁₆ alkyl, a C₁₈ alkyl, and thelike, can also be used in this invention. In formula (I-A), R can be analkenyl group, examples of which include, but are not limited to,ethenyl, propenyl, butenyl, pentenyl, hexenyl, heptenyl, octenyl,nonenyl, decenyl, and the like, as well as C₁₄ alkenyl, C₁₅ alkenyl, C₁₆alkenyl, or C₁₈ alkenyl groups.

In one aspect of the present invention, R is a hydrogen atom. In anotheraspect, R is a methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl,octyl, nonyl, decyl, or docedyl group. Yet, in another aspect, R is anethenyl, propenyl, butenyl, pentenyl, hexenyl, heptenyl, octenyl,nonenyl, or decenyl group. Additionally, R can be a hydrogen atom, amethyl group, an ethyl group, a propyl group, a butyl group, atert-butyl group, an octyl group, a nonyl group, a dodecyl group, a C₁₅alkyl group, or a C₁₅ alkenyl group, in other aspects of the presentinvention.

Each R′ in formula (I-A) independently is a hydrogen atom or a moietyhaving the formula (I-B) presented above. In one aspect of thisinvention, for instance, each R′ in formula (I-A) is a hydrogen atom. Informula (I-B), R is a hydrogen atom or a C₁-C₁₈ linear or branched alkylor alkenyl group, as discussed above. The integer t in formula (I-B) is0, 1, or 2, and each R″ in formula (I-B) independently is a hydrogenatom or a moiety having the formula (I-C) presented above. In formula(I-C), R is as defined above, a hydrogen atom or a C₁-C₁₈ linear orbranched alkyl or alkenyl group. The integer u in formula (I-C) is 0, 1,or 2.

Each X in formulas (I-A), (I-B), and (I-C) independently is apolyoxyalkylene moiety or a moiety having the formula:

wherein:

R₁ is a C₂-C₈ linear or branched alkanediyl; and

n is an integer in a range from 0 to 50, inclusive.

Generally, the polyoxyalkylene moiety comprises propyl ether repeatingunits, ethyl ether repeating units, or a combination thereof. Forinstance, the polyoxyalkylene moiety can be:

wherein p, q, r, and s, independently, are integers in a range from 0 to50, inclusive. Formulas (III) and (IV) above are not designed to showstereochemistry or isomeric positioning of the different moieties (e.g.,these formulas are not intended to show cis or trans isomers), althoughsuch compounds are contemplated and encompassed by these formulas.

By describing R₁ in formula (II) as an “alkanediyl” moiety, Applicantsare specifying the number of carbon atoms in the R₁ moiety, along withthe number of hydrogen atoms required to conform to the rules ofchemical valence for that diyl moiety. For example, as illustrated inthe above formulas, the fact that R₁ is bonded to two other groups isconsistent with this description of an alkanediyl moiety.

Unless otherwise specified, alkanediyl groups described herein areintended to include all structural isomers, linear or branched, of agiven moiety; for example, all enantiomers and all diastereomers areincluded within this definition. As an example, unless otherwisespecified, the term propanediyl is meant to include 1,1-propanediyl,1,2-propanediyl, 1,3-propanediyl, and 2,2-propanediyl. Similarly,butanediyl is meant to include all stereo and regio diyl isomers ofbutane, for example, n-butane-1,1-diyl, n-butane-1,2-diyl,n-butane-1,3-diyl, n-butane-1,4-diyl, n-butane-2,3-diyl,2-methylpropane-1,1-diyl, 2-methylpropane-1,3-diyl, and so forth.

It is within the scope of the present invention that R₁ in formula (II)is a C₂-C₃ linear or branched alkanediyl. In another aspect, R₁ is aC₃-C₈ linear or branched alkanediyl. In yet another aspect, R₁ is aC₃-C₆ linear or branched alkanediyl. For example, R₁ can be a C₃ or a C₆linear alkanediyl.

The Mannich based derivative compositions of the present invention canbe described as polymers, indicating that the compounds within thecompositions can comprise at least one repeating unit. Applicants' useof the term “polymer” is meant to include all molecular weight polymers,including lower molecular weight polymers or oligomers. Since there isnot an industry accepted cutoff in molecular weight between a polymerand an oligomer, Applicants have elected to use the term polymerthroughout this disclosure and intend for the term polymer to encompassoligomers as well.

Since compounds of the present invention are polymeric, the compositionsnecessarily include mixtures of different size molecules, with differentnumbers of repeating units. Further, for a polymeric Mannich basecomposition comprising amine compounds having the formulas disclosedabove, the integers n, p, q, r, and s, respectively and independently,can be zero.

For instance, the moiety within the brackets of formula (II) illustratesa repeating unit in a given molecule or compound, where the integer “n”represents the number of repeating units in that molecule or compound.Since the Mannich base derivative composition of the present inventionrepresented by formula (I-A) is polymeric, it is represented by amixture of molecules or compounds of various sizes, i.e., various valuesof n. It is within the scope of the present invention for the integer nto vary from 0 to 50 or more. In a different aspect, n in formula (II)ranges from 0 to 40, or from 0 to 30, or from 0 to 20, inclusive. In afurther aspect, n ranges from 0 to 10, inclusive.

In a different aspect of the present invention, the integer n in formula(II) ranges from 1 to 50, for example, from 1 to 40, or from 1 to 30,inclusive. The integer n can range from 1 to 20, inclusive, in anotheraspect of the present invention. Further, n is an integer in a rangefrom 1 to 10, inclusive, in still another aspect of the presentinvention. Yet, in another aspect, n is an integer in a range from 1 to6, inclusive. It is understood that n represents an integer designatingthe number of repeating units for a single molecule or compound withinthe polymeric composition, where the polymeric composition has adistribution of values of n, a distribution of molecular sizes, and adistribution of molecular weights.

Similarly, the moiety having the formula (III) comprises a propyl etherrepeating unit. One of skill in the art would recognize that suchpolymeric repeating units can be derived in a manner similar topropylene oxide polymerization. In formula (III), the integer “p”represents the number of repeating units in a molecule or compoundwithin the polymeric composition. It is within the scope of the presentinvention for the integer p to vary from 0 to 50 or more. Alternatively,p in formula (III) ranges from 0 to 40, from 0 to 30, or from 0 to 20,inclusive. In a different aspect, p ranges from 0 to 10, inclusive. Inaccordance with another aspect of the present invention, however, p isin a range from 1 to 50, for example, from 1 to 30, from 1 to 20, orfrom 1 to 10, inclusive. The integer p can fall within a range from 1 to6, inclusive, in yet another aspect of this invention.

The moiety having the formula (IV) comprises propyl ether and ethylether repeating units. One of ordinary skill in the art would recognizethat such polymeric repeating units can be derived in a manner similarto ethylene oxide and propylene oxide polymerization, where apolyethylene oxide chain has been capped with polypropylene oxiderepeating units. In formula (IV), the integers “q”, “r”, and “s”represent the number of repeating units in a molecule or compound withinthe polymeric composition. It is within the scope of the presentinvention for each of these integers, independently, to range from 0 to50 or more. In some cases, these integers, independently, fall within arange from 0 to 30, or from 0 to 20, inclusive. For example, theintegers q, r, and s can vary independently from 0 to 10, or from 0 to6, inclusive. Alternatively, the integers q, r, and s can varyindependently from 1 to 40, from 1 to 30, or from 1 to 20, in anotheraspect of the present invention. Yet, in another aspect, the integers q,r, and s range independently from 1 to 10, or from 1 to 6, inclusive.

In accordance with the present invention, methods of making these novelpolymeric Mannich base derivative compositions are disclosed. One of thereactants used to produce these novel compositions is an N,N′-dimethylsecondary diamine polymer, or methylamine-terminated polymer, such as,for example, methylamine-terminated poly-(N-methylazetidine) ormethylamine-terminated polyoxypropylene. These polymeric materials, andmethods for synthesizing these materials, are disclosed in U.S. patentapplication Ser. No. 11/584,388, filed on Oct. 20, 2006, which isincorporated herein by reference in its entirety.

The M_(n) data of these N,N′-dimethyl secondary diamine polymers, andthe data presented in Examples 1-5 that follow, were determined using aGas Chromatography (GC) technique. This procedure used a Hewlett-Packard6890 Gas Chromatograph equipped with a flame ionization detector. Theinlet was operated at 275° C. with a 10:1 split ratio. The GC techniqueused an initial temperature of 50° C. with an initial hold time of 2minutes, followed by increasing the temperature at a rate of 7° C. perminute, up to a maximum temperature of 285° C. The maximum temperaturewas held for an additional 30 minutes. The column was a nominal 30 meterHP-5 (5% phenyl methyl silicone, 95% dimethyl silicone) capillary columnwith a nominal diameter of 530 μm and a nominal film thickness of 2.65μm. The initial flow rate of helium was 4.2 mL/min.

The M_(n) was determined by assuming that the mass of eluting materialwas proportional to the area percent obtained by this GC technique.Reaction by-products were not included in the M_(n) calculation, andonly polymeric species with sufficient volatility to elute under the GCconditions given above were included in the calculation. The M_(n) wasdetermined by dividing each area percent (proportional to mass) by themolecular weight of that particular polymeric species to yield therelative moles of that species. The sum of the relative moles of thepolymeric species was then divided into the total area percent of thepolymeric species to give M_(n). The total area percent excludes thearea percent of reaction by-products. As will be recognized by thoseskilled in the art, as M_(n) increases, at some point an alternativetechnique such as Gel Permeation Chromatography (GPC) can be employedfor the measurement of M_(n), due to the low volatility of the highermolecular weight species in the distribution. For some N,N′-dimethylsecondary diamine polymers, this occurs when M_(n) exceeds about 400.

Illustrative examples of N,N′-dimethyl secondary diamine polymers whichcan be used to produce Mannich base derivative compositions inaccordance with the present invention include, but are not limited to,methylamine-terminated poly-(N-methylazetidine), methylamine-terminatedpolyoxypropylene, methylamine-terminated polyoxypropylenepolyoxyethylene copolymers, methylamine-terminatedpoly-(N-methylazacycloheptane), and the like, or any combinationthereof. A non-limiting example of the synthesis ofmethylamine-terminated poly-(N-methylazacycloheptane) is illustrated inExample 1, while non-limiting examples of the synthesis ofmethylamine-terminated poly-(N-methylazetidine) are demonstrated inExamples 2-5. A constructive example of the synthesis ofmethylamine-terminated polyoxypropylene is shown in Constructive Example6 that follows. Additional information on these materials can be foundin U.S. patent application Ser. No. 11/584,388, filed on Oct. 20, 2006,the disclosure of which is incorporated herein by reference in itsentirety.

One method of making a polymeric Mannich base derivative composition ofthe present invention comprises contacting at least one aldehydecompound, at least one phenol compound, and at least one N,N′-dimethylsecondary diamine polymer having a number-average molecular weight(M_(n)) from about 140 to about 1000. The compounds produced also can bereferred to as Mannich base derivatives of an N,N′-dimethyl secondarydiamine polymer. Generally, in this method of synthesis, the molar ratioof the at least one aldehyde compound to the at least one phenolcompound is less than or equal to about 3:1, and the molar ratio of theat least one N,N′-dimethyl secondary diamine polymer to the at least onealdehyde compound is greater than or equal to about 1:1. Non-limitingexamples of the synthesis of Mannich base derivative compositions inaccordance with this method of the present invention are illustrated inExamples 18-25.

Mannich bases are the condensation products of phenol or substitutedphenols, multifunctional amines, and an aldehyde, for example,formaldehyde. A commonly employed phenol stream used for the preparationof Mannich bases is cardanol, which comprises phenol substituted withC₁₅ unsaturated fatty chains in the meta position. These latter Mannichbases are often referred to in the industry as phenalkamines. One methodfor the preparation of Mannich bases is the direct reaction of at leastone phenol or substituted phenol, at least one multifunctional amine,and least one aldehyde, such as formaldehyde. This method ofsynthesizing a Mannich base is illustrated in the general reactionscheme presented below, where the multifunctional amine is a di-primaryamine:

The preparation of Mannich bases from phenols, aldehydes and primary orsecondary amines or ammonia is well known to those of skill in the art.For example, J. March, Advanced Organic Chemistry, Third Ed., John Wileyand Sons, New York, 1985, pages 496 and 800-802, which are incorporatedherein by reference, provides general Mannich base reaction schemes.

Conventional Mannich base compounds known in the art (i.e., not thepolymeric Mannich base derivative compositions of the present invention)have been employed in amine-epoxy formulations because, generally, theycure quickly at low temperatures. However, amine-epoxy coatings usingthese conventional Mannich base compounds often manifest blush,carbamate and exudate, and have poor flexibility. Further, Mannich basesproduced by this direct reaction generally contain large amounts ofresidual phenol. Phenol is a toxic chemical, and its presence at levelsgreater than 1% in a chemical mixture or composition generally requiresspecial disposal techniques, special labeling, and the use of personalprotective equipment to minimize worker exposure, all of which detractfrom the commercial acceptance of these products.

Attempts to adjust the stoichiometric ratio to drive the reaction tocomplete conversion of phenol generally causes the reaction to gelbefore the phenol content is reduced to less than about 1%. One way toavoid gelation is to adjust the stoichiometric ratio of reactants suchthat large quantities of residual phenol necessarily remain in the finalproduct. Thus, a typical recipe for a traditional Mannich base curingagent comprises approximately 1 mole of formaldehyde to about 2 to 3moles of phenol to about 3 moles of multifunctional amine. Generally,Mannich base derivative compositions of the present invention arenon-gelled compositions.

In accordance with one aspect of the present invention, a Mannich basederivative composition is provided. This composition comprises a Mannichbase reaction product of:

(a) at least one aldehyde compound;

(b) at least one phenol compound; and

(c) at least one N,N′-dimethyl secondary diamine polymer having a M_(n)from about 140 to about 1000.

The at least one phenol compound employed in the preparation of theMannich base derivatives by this direct reaction process is phenol or amono-substituted C₁ to C₁₈ alkyl phenol or alkenyl phenol. All isomers(ortho, meta and para) of the mono-substituted phenol may be employed.Non-limiting examples of suitable phenol compounds include phenol,cresol, butylphenol, t-butylphenol, octylphenol, nonylphenol,dodecylphenol, cardanol, and the like, or combinations thereof. Cardanolis derived from cashew nut shell liquid and contains a phenolsubstituted with C₁₅ saturated and unsaturated fatty chains in the metaposition.

For the at least one aldehyde compound, formaldehyde can be used in anyof the commercially available forms (e.g., a liquid form) employed forconventional condensation reactions, which are well known to thoseskilled in the art. The liquid form of formaldehyde may includepolymeric formaldehyde species also known as paraformaldehyde. Formalinis another form of formaldehyde that may be employed. Other C₂ to C₁₂aldehydes can also be employed in the direct Mannich base reaction.

Typically, the molar ratio of the at least one aldehyde compound (e.g.,formaldehyde) to the at least one phenol compound (e.g., unsubstitutedphenol) employed in the preparation of the Mannich base derivative of anN,N′-dimethyl secondary diamine polymer will be less than or equal toabout 3:1. If the ratio is much greater than about 3:1, it is generallybelieved that the excess formaldehyde (or other aldehyde compound) willcouple amines with a methylene unit, which could subsequently behydrolyzed by atmospheric water when the composition is employed to cureepoxy resins, resulting in the release of formaldehyde. With amono-substituted alkyl phenol or alkenyl phenol, the molar ratio of theat least one aldehyde compound to the at least one phenol compound isgenerally less than about 2:1.

The lower limit on the molar ratio of the at least one aldehyde compoundto the at least one phenol compound for some applications is about 1:1.As this ratio decreases, it becomes increasingly more difficult todecrease the concentration of residual free phenols. Furthermore, theconcentration of phenolic OH groups in the overall composition isreduced, which tends to decrease the rate of reaction of the Mannichbase compounds with epoxy resins, often resulting in longer curing timesfor amine-epoxy compositions.

In accordance with one aspect of the invention employing unsubstitutedphenol, the molar ratio of formaldehyde or other aldehyde compound tophenol is within a range from about 2:1 to about 3:1. For example, themolar ratio can be in a range from about 2.2:1 to about 3:1, or fromabout 2.5:1 to about 2.9:1. In an aspect of the invention employing amono-substituted phenol, at the meta position, the molar ratio offormaldehyde or other aldehyde to the at least one phenol compound isfrom about 1:1 to about 3:1, such as, for example, from about 1.3:1 toabout 2.5:1, or from about 1.5:1 to about 1.9:1. In an aspect employinga mono-substituted phenol, at the ortho or para position, the molarratio of formaldehyde or other aldehyde to the at least one phenolcompound is from about 1:1 to about 2.5:1. Further, the molar ratio canbe from about 1:1 to about 2:1, or from about 1.5:1 to about 1.9:1.

The molar ratio of the at least one N,N′-dimethyl secondary diaminepolymer to the at least one aldehyde compound (e.g., formaldehyde) isgenerally greater than or equal to about 1:1 to minimize the viscosityof the final product, and to prevent gelation in cases whereunsubstituted phenol is employed as the at least one phenol compound.However, if a higher viscosity product is desired, lower molar ratioscan be employed, so long as the reaction product does not gel. Inaccordance with one aspect of the present invention, the molar ratio ofat least one N,N′-dimethyl secondary diamine polymer to the at least onealdehyde compound (e.g., formaldehyde) ranges from about 1:1 to about3:1, for example, about 1:1 to about 2.5:1. Molar ratios above about2.5:1 can be employed, but the phenolic OH concentration will be reducedas dictated by the formaldehyde to phenol ratios described above. Thiswill likely also increase the level of free amine, which tends tonegatively impact the surface appearance of amine-epoxy coatings. Inanother aspect, the molar ratio of the at least one diamine polymer tothe at least one aldehyde compound is in a range from about 1.2:1 toabout 1.8:1.

Various modifications of the general procedure for the preparation ofthe Mannich base compounds by the direct process described above can beused, and are within the scope of this invention. For example, phenol(or substituted phenol) and formaldehyde (or other aldehyde compound)can be mixed together and heated to about 100° C., followed by theaddition of the N,N′-dimethyl secondary diamine polymer. Additionalheating and removal of water via distillation yields the Mannich basederivative. Alternatively, a pre-mixed solution of phenol (orsubstituted phenol) and formaldehyde (or other aldehyde compound) can beadded to the N,N′-dimethyl secondary diamine polymer, followed bydistillation to remove water. In another procedure, formaldehyde (orother aldehyde compound) can be added to the N,N′-dimethyl secondarydiamine polymer, followed by the addition of the phenol compound,heating, and then distilling to remove water. Also, the N,N′-dimethylsecondary diamine polymer and the phenol compound can be mixed together,followed by the addition of formaldehyde (or other aldehyde compound)and the removal of water.

In one aspect of the present invention, the phenol or substituted phenolis contacted with the N,N′-dimethyl secondary diamine polymer. Liquidformaldehyde is then added to the reaction mixture at room temperatureor slightly elevated temperature, so that the exotherm is controlled.The reaction mixture is subsequently heated to complete the reaction.The reaction temperature is generally in the range from about 50 toabout 100° C., although higher or lower temperatures than these can beemployed. In another aspect, the reaction temperature ranges from about70 to about 90° C. After reaching reaction completion, the temperatureis then increased to remove water, and methanol if formalin was employedas the formaldehyde source.

Generally, the at least one aldehyde compound, the at least one phenolcompound, and the at least one N,N′-dimethyl secondary diamine polymercan be contacted in any order or sequence, and subsequently reacted toform the resultant Mannich base derivative composition.

A Mannich base derivative composition, therefore, can comprise a Mannichbase reaction product of at least one aldehyde compound, at least onephenol compound, and at least one N,N′-dimethyl secondary diaminepolymer having a M_(n) from about 140 to about 1000. Generally, themolar ratio of the at least one aldehyde compound to the at least onephenol compound is less than or equal to about 3:1, and the molar ratioof the at least one N,N′-dimethyl secondary diamine polymer to the atleast one aldehyde compound is greater than or equal to about 1:1. Inthese and other aspects, the at least one aldehyde compound can compriseformaldehyde. In another aspect, the at least one phenol compoundcomprises phenol, cresol, t-butyl phenol, nonyl phenol, cardanol, or acombination thereof. In yet another aspect, the at least oneN,N′-dimethyl secondary diamine polymer comprises methylamine-terminatedpoly-(N-methyl-azetidine), methylamine-terminatedpoly-(N-methyl-azacycloheptane), or a combination thereof.

The Mannich base derivative composition comprising a reaction product ofat least one aldehyde compound, at least one phenol compound, and atleast one N,N′-dimethyl secondary diamine polymer generally has an AHEWfrom about 98 to about 1350. In another aspect, this composition has anAHEW in the range from about 100 to about 1200, or from about 105 toabout 1000. In yet another aspect, the AHEW is in a range from about 105to about 800, from about 105 to about 600, or from about 105 to about400. For example, the AHEW of the Mannich base derivative composition,in this aspect, can be in a range from about 115 to about 300.

Similarly, the amine value of this Mannich base derivative compositiontypically falls within a range from about 85 to about 910 mg KOH/g. Theamine value of this composition can be within a range from about 100 toabout 910, from about 130 to about 900, or from about 200 to about 890,in other aspects of this invention. For example, the amine value can bein a range from about 300 to about 890. In another aspect, the aminevalue is in a range from about 400 to about 900, from about 500 to about900, or from about 600 to about 900. In a different aspect, the aminevalue of the Mannich base derivative composition is in a range fromabout 700 to about 880.

In accordance with another aspect of the present invention, a Mannichbase derivative composition is provided which comprises a reactionproduct of:

(a) at least one di-substituted or tri-substituted Mannich basecompound; and

(b) at least one N,N′-dimethyl secondary diamine polymer having a M_(n)from about 140 to about 1000.

This composition employs an exchange reaction, which can producesubstantially phenol-free Mannich base derivatives of at least oneN,N′-dimethyl secondary diamine polymer. Generally, the molar ratio ofthe at least one N,N′-dimethyl secondary diamine polymer to the at leastone di-substituted or tri-substituted Mannich base compound is in arange from about 1:1 to about 6:1. Non-limiting examples of thesynthesis of Mannich base derivative compositions in accordance withthis method of the present invention are illustrated in Examples 7-10and 26.

In one aspect, the at least one di-substituted or tri-substitutedMannich base compound comprises bis-(dimethylaminomethyl)phenol,tris-(dimethylaminomethyl) phenol, or a combination thereof. The atleast one N,N′-dimethyl secondary diamine polymer can comprisemethylamine-terminated poly-(N-methyl-azetidine), methylamine-terminatedpoly-(N-methyl-azacycloheptane), or a combination thereof, in anotheraspect of this invention. Yet, in another aspect, the at least oneN,N′-dimethyl secondary diamine polymer can comprise a polyoxyalkylenediamine, such as methylamine-terminated polyoxypropylene or amethylamine-terminated polyoxypropylene polyoxyethylene copolymer. In anexchange reaction involving tris-(dimethylaminomethyl)phenol, forexample, dimethylamine is substituted by the diamine polymer to yieldthe Mannich base derivatives of the present invention. Thetri-substituted Mannich base compound, tris-(dimethylaminomethyl)phenol,is commercially available from Air Products and Chemicals, Inc., asAncamine® K54.

The Mannich base compounds utilized in the exchange process can bederived from the same phenols referred to above in describing the directreaction process, such as, phenol, t-butylphenol, and cardanol. Thesecondary amine used for exchange can be any secondary amine ofsufficient volatility to be easily removed from the reaction mixture bydistillation. As it pertains to the present invention, therefore, it isbeneficial if the boiling point of the secondary amine is sufficientlydifferent from the boiling point of the diamine polymer used. Suitablesecondary amines include, but are not limited to, dimethylamine,diethylamine, dipropylamine, dibutylamine, piperidine, pyrrolidine,morpholine, methylpiperazine, and the like, or combinations thereof.

Typically, the lower limit of the molar ratio of the at least oneN,N′-dimethyl secondary diamine polymer to the at least onetri-substituted Mannich base compound (e.g.,tris-(dimethylaminomethyl)phenol) is the molar ratio which still yieldsa non-gelled reaction product. Often, the molar ratio of the at leastone diamine polymer to the at least one tri-substituted Mannich basecompound is in a range from about 2:1 to about 6:1, for example, about3:1 to about 4.5:1. When conducting the exchange reaction with adi-substituted Mannich base compound, the molar ratio of the at leastone diamine polymer to the at least one di-substituted Mannich basecompound employed can be in a range from about 1:1 to about 4.5:1. Inanother aspect, the molar ratio is in range from about 2:1 to about 3:1.As the molar ratio is decreased, the viscosity of the reaction productgenerally increases. Conversely, as the molar ratio is increased,generally the level of free diamine polymer will increase, as will thecure time with an epoxy resin.

An amine exchange reaction of the present invention can be conducted byheating and contacting the at least one di-substituted ortri-substituted Mannich base compound with the at least oneN,N′-dimethyl secondary diamine polymer, generally while agitating, totemperatures of at least about 100° C. In other aspects, the reactiontemperature can be within a range from about 130° C. to about 220° C.,or from about 140° C. to about 180° C. Optionally, the reactants can becontacted in the presence of an inert solvent or diluent. The secondaryamine which is liberated in the reaction can be distilled into a cooledreceiver.

The Mannich base derivative composition comprising a reaction product ofat least one di-substituted or tri-substituted Mannich base compound andat least one N,N′-dimethyl secondary diamine polymer generally has anAHEW from about 107 to about 2100. In another aspect, this compositionhas an AHEW in the range from about 110 to about 1500, or from about 110to about 1000. In yet another aspect, the AHEW is in a range from about110 to about 800, from about 110 to about 600, or from about 115 toabout 400. For example, the AHEW of the Mannich base derivativecomposition, in this aspect, can be in a range from about 115 to about300.

Similarly, the amine value of this Mannich base derivative compositiontypically falls within a range from about 130 to about 900 mg KOH/g. Theamine value of this composition can be within a range from about 150 toabout 910, from about 200 to about 900, or from about 250 to about 890,in other aspects of this invention. For example, the amine value can bein a range from about 300 to about 890. In another aspect, the aminevalue is in a range from about 400 to about 900, from about 500 to about900, or from about 600 to about 900. In a different aspect, the aminevalue of the Mannich base derivative composition is in a range fromabout 700 to about 880.

Multifunctional Amine

Compositions in accordance with the present invention can comprise atleast one multifunctional amine. Multifunctional amine, as used herein,describes compounds with amine functionality and which contain three (3)or more active amine hydrogens.

It can be beneficial to limit the volatility of the specificmultifunctional amine used in some applications where worker exposureand safety issues may arise. Thus, in one aspect of the presentinvention, the at least one multifunctional amine contains 6 or morecarbon atoms. In another aspect, the at least one multifunctional aminecontains 8 or more carbon atoms. In yet another aspect, the at least onemultifunctional amine contains 12 or more carbon atoms.

Non-limiting examples of multifunctional amines that are within thescope of the present invention include, but are not limited to, analiphatic amine; a cycloaliphatic amine; an aromatic amine; a Mannichbase derivative of an aliphatic amine, a cycloaliphatic amine, or anaromatic amine; a polyamide derivative of an aliphatic amine, acycloaliphatic amine, or an aromatic amine; an amidoamine derivative ofan aliphatic amine, a cycloaliphatic amine, or an aromatic amine; anamine adduct derivative of an aliphatic amine, a cycloaliphatic amine,or an aromatic amine; and the like; or any combination thereof. TheMannich base derivatives disclosed in this section are not the Mannichbase derivatives of N,N′-dimethyl secondary diamine polymers of thepresent invention.

More than one multifunctional amine can be used in the compositions ofthe present invention. For example, the at least one multifunctionalamine can comprise an aliphatic amine and a Mannich base derivative of acycloaliphatic amine. Also, the at least one multifunctional amine cancomprise one aliphatic amine and one different aliphatic amine.

Exemplary aliphatic amines include polyethylene amines(triethylenetetramine, tetraethylenepentamine, pentaethylenehexamine andthe like), 1,6-hexanediamine, 3,3,5-trimethyl-1,6-hexanediamine,3,5,5-trimethyl-1,6-hexanediamine, 2-methyl-1,5-pentanediamine(commercially available as Dytek-A), bis-(3-aminopropyl)amine,N,N′-bis-(3-aminopropyl)-1,2-ethanediamine, aminoethylpiperazine, andthe like, or combinations thereof. Additionally, the poly(alkyleneoxide) diamines and triamines commercially available under the Jeffaminename from Huntsman Corporation, are useful in the present invention.Illustrative examples include, but are not limited to, Jeffamine® D-230,Jeffamine® D-400, Jeffamine® D-2000, Jeffamine® D-4000, Jeffamine®T-403, Jeffamine® EDR-148, Jeffamine® EDR-192, Jeffamine® C-346,Jeffamine® ED-600, Jeffamine® ED-900, Jeffamine® ED-2001, and the like,or combinations thereof.

Cycloaliphatic and aromatic amines include, but are not limited to,1,2-diaminocyclohexane, 1,3-diaminocyclohexane, 1,4-diaminocyclohexane,hydrogenated ortho-toluenediamine, hydrogenated meta-toluenediamine,metaxylylene diamine, hydrogenated metaxylylene diamine (referred tocommercially as 1,3-BAC), isophorone diamine, various isomers ofnorbornane diamine, 3,3′-dimethyl-4,4′-diaminodicyclohexyl methane,4,4′-diaminodicyclohexyl methane, 2,4′-diaminodicyclohexyl methane, amixture of methylene bridged poly(cyclohexyl-aromatic)amines, and thelike, or combinations thereof. The mixture of methylene bridgedpoly(cyclohexyl-aromatic)amines is abbreviated as either MBPCAA or MPCA,and is described in U.S. Pat. No. 5,280,091, which is incorporatedherein by reference in its entirety. In one aspect of the presentinvention, the at least one multifunctional amine is a mixture ofmethylene bridged poly(cyclohexyl-aromatic)amines (MPCA).

Mannich base derivatives suitable for use as a multifunctional amine canbe made by the reaction of the above described aliphatic amines,cycloaliphatic amines, or aromatic amines with phenol or a substitutedphenol and formaldehyde. An exemplary substituted phenol used to makeMannich bases with utility in the present invention is cardanol, whichis obtained from cashew nut shell liquid. Alternatively, Mannich basescan be prepared by an exchange reaction of a multifunctional amine witha tertiary amine containing a Mannich base, such astris-(dimethylaminomethyl)phenol (commercially available as Ancamine®K54 from Air Products and Chemicals, Inc.) orbis-(dimethylaminomethyl)phenol. Polyamide derivatives can be preparedby the reaction of an aliphatic amine, cycloaliphatic amine, or aromaticamine with dimer fatty acid, or mixtures of a dimer fatty acid and afatty acid. Amidoamine derivatives can be prepared by the reaction of analiphatic amine, cycloaliphatic amine, or aromatic amine with fattyacids. Amine adducts can be prepared by the reaction of an aliphaticamine, cycloaliphatic amine, or aromatic amine with an epoxy resin, forexample, with the diglycidyl ether of bisphenol-A, the diglycidyl etherof bisphenol-F, or epoxy novolac resins. The aliphatic, cycloaliphatic,and aromatic amines also can be adducted with monofunctional epoxyresins, such as phenyl glycidyl ether, cresyl glycidyl ether, butylglycidyl ether, other alkyl glycidyl ethers, and the like.

Multifunctional Epoxy Resin

Amine-epoxy compositions of the present invention comprise an epoxycomponent, the epoxy component comprising at least one multifunctionalepoxy resin. Multifunctional epoxy resin, as used herein, describescompounds containing 2 or more 1,2-epoxy groups per molecule. Epoxidecompounds of this type are described in Y. Tanaka, “Synthesis andCharacteristics of Epoxides”, in C. A. May, ed., Epoxy Resins Chemistryand Technology (Marcel Dekker, 1988), which is incorporated herein byreference.

One class of epoxy resins suitable for use in the present inventioncomprise the glycidyl ethers of polyhydric phenols, including theglycidyl ethers of dihydric phenols. Illustrative examples include, butare not limited to, the glycidyl ethers of resorcinol, hydroquinone,bis-(4-hydroxy-3,5-difluorophenyl)-methane,1,1-bis-(4-hydroxyphenyl)-ethane,2,2-bis-(4-hydroxy-3-methylphenyl)-propane,2,2-bis-(4-hydroxy-3,5-dichlorophenyl) propane,2,2-bis-(4-hydroxyphenyl)-propane (commercially known as bisphenol A),bis-(4-hydroxyphenyl)-methane (commercially known as bisphenol F, andwhich may contain varying amounts of 2-hydroxyphenyl isomers), and thelike, or any combination thereof. Additionally, advanced dihydricphenols of the following structure also are useful in the presentinvention:

where t is an integer, and R^(B) is a divalent hydrocarbon radical of adihydric phenol, such as those dihydric phenols listed above. Materialsaccording to this formula can be prepared by polymerizing mixtures of adihydric phenol and epichlorohydrin, or by advancing a mixture of adiglycidyl ether of the dihydric phenol and the dihydric phenol. Whilein any given molecule the value of t is an integer, the materials areinvariably mixtures which can be characterized by an average value of twhich is not necessarily a whole number. Polymeric materials with anaverage value of t between 0 and about 7 can be used in one aspect ofthe present invention.

In another aspect, epoxy novolac resins, which are the glycidyl ethersof novolac resins, can be used as multifunctional epoxy resins inaccordance with the present invention. In yet another aspect, the atleast one multifunctional epoxy resin is a diglycidyl ether ofbisphenol-A (DGEBA), an advanced or higher molecular weight version ofDGEBA, a diglycidyl ether of bisphenol-F, an epoxy novolac resin, or anycombination thereof. Higher molecular weight versions or derivatives ofDGEBA are prepared by the advancement process, where excess DGEBA isreacted with bisphenol-A to yield epoxy terminated products. The epoxyequivalent weights (EEW) for such products ranges from about 450 to 3000or more. Because these products are solid at room temperature, they areoften referred to as solid epoxy resins.

DGEBA or advanced DGEBA resins are often used in coating formulationsdue to a combination of their low cost and generally high performanceproperties. Commercial grades of DGEBA having an EEW ranging from about174 to about 250, and more commonly from about 185 to about 195, arereadily available. At these low molecular weights, the epoxy resins areliquids and are often referred to as liquid epoxy resins. It isunderstood by those skilled in the art that most grades of liquid epoxyresin are slightly polymeric, since pure DGEBA has an EEW of 174. Resinswith EEW's between 250 and 450, also generally prepared by theadvancement process, are referred to as semi-solid epoxy resins becausethey are a mixture of solid and liquid at room temperature.

Depending upon the end-use application, it can be beneficial to reducethe viscosity of the compositions of the present invention by modifyingthe epoxy component. For example, the viscosity can be reduced to allowan increase in the level of pigment in a formulation or compositionwhile still permitting easy application, or to allow the use of a highermolecular weight epoxy resin. Thus, it is within the scope of thepresent invention for the epoxy component, which comprises at least onemultifunctional epoxy resin, to further comprise a monofunctionalepoxide. Examples of monoepoxides include, but are not limited to,styrene oxide, cyclohexene oxide, ethylene oxide, propylene oxide,butylene oxide, and the glycidyl ethers of phenol, cresols,tert-butylphenol, other alkyl phenols, butanol, 2-ethylhexanol, C₄ toC₁₄ alcohols, and the like.

Miscellaneous Additives

Compositions of the present invention can be used to produce variousarticles of manufacture. Depending on the requirements during themanufacturing of or for the end-use application of the article, variousadditives can be employed in the formulations and compositions to tailorspecific properties. These additives include, but are not limited to,solvents, accelerators, plasticizers, fillers, fibers such as glass orcarbon fibers, pigments, pigment dispersing agents, rheology modifiers,thixotropes, flow or leveling aids, defoamers, or any combinationthereof. It is understood that other mixtures or materials that areknown in the art can be included in the compositions or formulations andare within the scope of the present invention.

Further, compositions within the scope of the present invention can besolventless, also referred to as solvent-free or 100% solids.Alternatively, these compositions can further comprise at least onesolvent (a solvent is also referred to as a diluent). Often, a solventor mixture of solvents is chosen to give a specific evaporation rateprofile for the composition or formulation, while maintaining solubilityof the components of the formulation.

Articles

The present invention also is directed to articles of manufacturecomprising the compositions disclosed herein. For example, an articlecan comprise a cured amine-epoxy composition which comprises the contactproduct of an amine curing agent component and an epoxy component. Theamine curing agent component can comprise at least one Mannich basederivative of an N,N′-dimethyl secondary diamine polymer and at leastone multifunctional amine. The epoxy component can comprise at least onemultifunctional epoxy resin. Optionally, various additives can bepresent in the compositions or formulations used to produce fabricatedarticles, dependent upon the desired properties. These additives caninclude, but are not limited to, solvents, accelerators, plasticizers,fillers, fibers such as glass or carbon fibers, pigments, pigmentdispersing agents, rheology modifiers, thixotropes, flow or levelingaids, defoamers, or any combination thereof.

Articles in accordance with the present invention include, but are notlimited to, a coating, an adhesive, a construction product, a flooringproduct, or a composite product. Coatings based on these amine-epoxycompositions can be solvent-free or can contain solvents or diluents asneeded for the particular application. For example, coatings with solidscontent greater than 50%, greater than 65%, greater than 75%, or greaterthan 85%, are within the scope of the present invention. Coatings cancontain various types and levels of pigments for use in paintapplications.

Numerous substrates are suitable for the application of coatings of thisinvention with proper surface preparation, as is well known to one ofordinary skill in the art. Such substrates include, but are not limitedto, concrete and various types of metals and alloys, such as steel andaluminum. For example, the low temperature cure, good surface appearancewhen applied at room temperature, and good flexibility properties of thecoatings of the present invention make them suitable for the painting orcoating of large metal objects or cementitious substrates which must bepainted and/or cured at room temperature or colder conditions, includingships, bridges, industrial plants and equipment, and floors. Coatings ofthis invention can be applied and cured at temperatures ranging fromabout −10° C. to about 50° C., or alternatively, at temperatures rangingfrom about 0° C. to about 35° C. As needed, these coatings also can beforce cured at higher temperatures, which often can improve theflexibility of the cured material.

Coatings of this invention can be applied by any number of techniquesincluding spray, brush, roller, paint mitt, and the like. In order toapply very high solids content or 100% solids coatings of thisinvention, plural component spray application equipment can be used, inwhich the amine and epoxy components are mixed in the lines leading tothe spray gun, in the spray gun itself, or by mixing the two componentstogether as they leave the spray gun. Using this technique can alleviatelimitations with regard to the pot life of the formulation, whichtypically decreases as both the amine reactivity and the solids contentincreases. Heated plural component equipment can be employed to reducethe viscosity of the components, thereby improving ease of application.

Construction and flooring applications include compositions comprisingthe amine-epoxy compositions of the present invention in combinationwith concrete or other materials commonly used in the constructionindustry. Compositions of the present invention can be used in theconstruction of epoxy-based floors, often in applications requiringbetter mechanical properties (e.g., improved tensile strength orimproved compressive strength) or better elongation than that normallyobtained from cementitious or other similar types of flooring materials.Crack injection and crack filling products also can be prepared from thecompositions disclosed herein, as well as polymer modified cements, tilegrouts, and the like. Non-limiting examples of composite products orarticles comprising amine-epoxy compositions disclosed herein includetennis rackets, skis, bike frames, airplane wings, glass fiberreinforced composites, and other molded products.

EXAMPLES

The invention is further illustrated by the following examples, whichare not to be construed in any way as imposing limitations to the scopeof this invention. Various other aspects, embodiments, modifications,and equivalents thereof which, after reading the description herein, maysuggest themselves to one of ordinary skill in the art without departingfrom the spirit of the present invention or the scope of the appendedclaims.

Coatings of amine-epoxy compositions were prepared and tested asfollows. Hardener mixtures or compositions, including amine compositionsin accordance with the present invention, were prepared by contactingand mixing the components given in the tables that follow. Therespective hardener mixture or composition, or the individual hardener,was then mixed with a multifunctional epoxy resin at the use levelindicated in the tables in parts per hundred weight resin (PHR). Theepoxy resin used in these examples was the diglycidyl ether ofbisphenol-A (DGEBA), grade D.E.R.™ 331 with an EEW in the range of 182to 192. This epoxy resin is commercially available from the Dow ChemicalCompany.

In Examples 11-17 and 27-41, clear coatings were applied to standardglass panels to produce samples for drying time testing using aBeck-Koller drying time recorder and for hardness development by thePersoz pendulum hardness method. Clear coatings for drying time by thethumb twist method and for specular gloss testing were applied touncoated, matte paper charts (AG5350, Byk). Coatings were applied atabout 75 μm WFT (wet film thickness) using a Bird bar applicatorresulting in dry film thicknesses ranging from approximately 60 to 70μm. Coatings of Examples 11-17 and 27-35 were cured either at 5° C. and80% RH (relative humidity) or 25° C. and 60% RH using a Weiss climatechamber (type WEKK0057). Coatings of Examples 36-41 were cured at 5° C.and 60% RH using the Weiss climate chamber. Persoz Hardness was measuredat the times indicated in the tables.

Clear coatings for impact resistance and mandrel bend testing wereapplied to respectively cold-rolled steel test panels, ground one side(approximate size 76 mm×152 mm×0.8 mm thick) and cold-rolled steel,smooth finish (approximate size 76 mm×152 mm×0.5 mm thick), using anominal 75 WFT wire bar. Metal test panels were obtained from Q PanelLab Products. Films were cured according to the following schedules: (A)14 days room temperature, room temperature being approximately 23° C.;(B) 14 days room temperature followed by 2 hours at 80° C.; or (C) 60days room temperature. Dry film thicknesses were from about 60 to 80 μmfollowing cure schedules A and C, and from about 50 to 55 μm followingschedule B.

The mix viscosities for Examples 11-17 were determined using a RheolabMC20 apparatus (Physica) equipped with a Viscotherm VT10 water bath andMC20 temperature control unit. The equipment was set up with the TEK 150cone-plate and connected to a computer. After the apparatus wasequilibrated at 25° C., the gap between the cone (MK22) and plate wasset to approximately 50 μm. Samples were equilibrated at 25° C. for 24hours before testing. After mixing as indicated, excess product runningout of the gap was removed and the rotational viscosity of the mixedproduct was recorded at a 200 reciprocal second shear rate after 30seconds.

Coating properties were measured in accordance with the standard testmethods listed in Table 1. Waterspot resistance is tested by placingdrops of water on the surface of the coating for a specified time andobserving the impact on the coating. This test is used in the industryto determine if the surface of the coating is damaged or aestheticallyimpacted by extended contact with water or moisture.

TABLE 1 Analytical test methods. Property Response Test Method DryingTime: Beck- Thin film set times, ASTM D5895 Koller Recorder phases 1, 2& 3 (hr) Drying Time: Thumb Set-to-touch and ASTM D1640 Twist Methoddry-to-handle time (hr) Specular Gloss Gloss at 20° and 60° ISO 2813,ASTM D523 Persoz Pendulum Persoz hardness (s) ISO 1522, ASTM D4366Hardness Impact Resistance - Direct and reverse ISO 6272, ASTM D2794Tubular Impact Tester impact (kg.cm) Mandrel Bend Test: Elongation (%)ISO 1519, ASTM D1737 Cylindrical Bend Mandrel Bend Test: Elongation (%)ISO 6860, ASTM D522 Conical Bend

Example 1 Synthesis of methylamine-terminatedpoly-(N-methylazacycloheptane)

135 g of adipodinitrile, 50 g of isopropanol, and 2.7 g of Pd/Al₂O₃catalyst were placed in a 1-liter stainless-steel batch pressure reactorequipped with a stirrer and 1-liter hydrogen ballast tank. The Pd/Al₂O₃catalyst is commercially available from the Johnson-Mathey Corporation.The reactor was sealed and subsequently purged with nitrogen andhydrogen to remove any air from the reactor. While stirring the reactorcontents, 85 g of anhydrous methylamine were added to the reactor. Thereactor was then pressurized with hydrogen to 1.72 MPa (250 psi), andheated to 120° C. These conditions were maintained until the rate ofhydrogen uptake from the ballast tank fell below 0.0034 MPa/min (0.5psi/min). When this occurred, the reactor pressure was raised to 5.86MPa (850 psi). These conditions were maintained until the rate ofhydrogen uptake from the ballast tank fell below 0.0034 MPa/min (0.5psi/min). The reactor was cooled to room temperature and depressurized,and the reaction product was filtered to remove the catalyst. Solventwas then removed by rotary evaporation. The resulting reaction productwas methylamine-terminated poly-(N-methylazacycloheptane) with anestimated amine hydrogen equivalent weight (ANEW) of about 121. TheM_(n) was determined to be approximately 184 using the GC techniquedescribed above. Methylamine-terminated poly-(N-methylazacycloheptane)has the following chemical structure:

The methylamine-terminated poly-(N-methylazacycloheptane) compound ofExample 1 is designated as dimethyl secondary diamine 1, abbreviatedDSD-1. DSD-1 was analyzed using gas chromatography (GC) and had thefollowing polymer distribution by area percent, with “others”representing reaction by-products which were not separated or identifiedusing GC, nor used in determining M_(n):

n = 0 47.6% n = 1 35.7% n = 2 5.8% Others 10.9%

Example 2 Synthesis of methylamine-terminated poly-(N-methylazetidine)

282 g of acrylonitrile and 8.5 g of water were placed in a 1-literstainless-steel batch pressure reactor equipped with a stirrer. Thereactor was sealed and subsequently purged with nitrogen to remove anyair from the reactor. While stirring the reactor contents, 200 g ofmethylamine were added to the reactor over a time period of 5 hours.During the addition of the methylamine, the reactor temperature wasmaintained in range of 55-60° C. This temperature range was thenmaintained for 1.5 hours after the methylamine addition was complete.The reactor was cooled and the intermediate product removed.

120 g of isopropanol and 7.5 g of Pd/Al₂O₃ catalyst were placed in a1-liter stainless-steel batch pressure reactor equipped with a stirrerand 1-liter hydrogen ballast tank. The Pd/Al₂O₃ catalyst is commerciallyavailable from the Johnson-Mathey Corporation. The reactor was sealedand subsequently purged with nitrogen and hydrogen to remove any airfrom the reactor. While stirring the reactor contents, 90 g of anhydrousmethylamine were added to the reactor. The reactor was then pressurizedwith hydrogen to 5.86 MPa (850 psi), and heated to 120° C. Over a timeperiod of 5 hours, 450 g of the intermediate product described abovewere added to the reactor. Substantially constant reactor conditionswere maintained for approximately 2 more hours after the addition of theintermediate product was complete, at which time the rate of hydrogenuptake from the ballast tank fell below 0.0034 MPa/min (about 0.5psi/min). The reactor was cooled to room temperature and depressurized,and the reaction product was filtered to remove the catalyst. Thesolvent was then removed by rotary evaporation. The resulting reactionproduct was methylamine-terminated poly-(N-methylazetidine) with anestimated ANEW of about 100. The M_(n) was determined to beapproximately 198 using the GC technique described above.Methylamine-terminated poly-(N-methylazetidine) has the followingchemical structure:

The methylamine-terminated poly-(N-methylazetidine) compound of Example2 is designated as dimethyl secondary diamine 2, abbreviated DSD-2.DSD-2 was analyzed using GC and had the following polymer distributionby area percent, with “others” representing reaction by-products whichwere not separated or identified using GC, nor used in determiningM_(n):

n = 0 12.6% n = 1 26.1% n = 2 25.5% n = 3 14.7% n = 4 7.3% n = 5 3.5%Others 10.3%

Example 3 Synthesis of methylamine-terminated poly-(N-methylazetidine)

282 g of acrylonitrile and 8.5 g of water were placed in a 1-literstainless-steel batch pressure reactor equipped with a stirrer. Thereactor was sealed and subsequently purged with nitrogen to remove anyair from the reactor. While stirring the reactor contents, 87 g ofmethylamine were added to the reactor over a time period of 5 hours.During the addition of the methylamine, the reactor temperature wasmaintained in range of 55-60° C. This temperature range was thenmaintained for 1.5 hours after the methylamine addition was complete.The reactor was cooled and the intermediate product removed.

120 g of isopropanol and 7 g of Pd/Al₂O₃ catalyst were placed in a1-liter stainless-steel batch pressure reactor equipped with a stirrerand 1-liter hydrogen ballast tank. The Pd/Al₂O₃ catalyst is commerciallyavailable from the Johnson-Mathey Corporation. The reactor was sealedand subsequently purged with nitrogen and hydrogen to remove any airfrom the reactor. While stirring the reactor contents, about 160 g ofanhydrous methylamine were added to the reactor. The reactor was thenpressurized with hydrogen to 5.86 MPa (850 psi), and heated to 120° C.Over a time period of 5 hours, 350 g of the intermediate productdescribed above were added to the reactor. Substantially constantreactor conditions were maintained for approximately 2 more hours afterthe addition of the intermediate product was complete, at which time therate of hydrogen uptake from the ballast tank fell below 0.0034 MPa/min(0.5 psi/min). The reactor was cooled to room temperature anddepressurized, and the reaction product was filtered to remove thecatalyst. The solvent was then removed by rotary evaporation. Theresulting reaction product was methylamine-terminatedpoly-(N-methylazetidine) with an estimated ANEW of about 113. The M_(n)was determined to be approximately 253 using the GC technique describedabove. Methylamine-terminated poly-(N-methylazetidine) has the followingchemical structure:

The methylamine-terminated poly-(N-methylazetidine) compound of Example3 is designated as dimethyl secondary diamine 3, abbreviated DSD-3.DSD-3 was analyzed using GC and had the following polymer distributionby area percent, with “others” representing reaction by-products whichwere not separated or identified using GC, nor used in determiningM_(n):

n = 0 2.8% n = 1 16.6% n = 2 18.2% n = 3 20.7% n = 4 12.2% n = 5 9.2%Others 20.3%

Example 4 Synthesis of methylamine-terminated poly-(N-methylazetidine)

142.5 parts by weight of acrylonitrile and 3 parts of water were placedin a 1-liter stainless-steel batch pressure reactor equipped with astirrer. The reactor was sealed and subsequently purged with nitrogen toremove any air from the reactor. While stirring the reactor contents,100 parts by weight of methylamine were added to the reactor over a timeperiod of 4 hours. During the addition of the methylamine, the reactortemperature was maintained at 55° C. This temperature was thenmaintained for 1.5 hours after the methylamine addition was complete.The reactor was cooled and the intermediate product removed.

35 parts by weight of isopropanol and 1.5 parts of Pd/Al₂O₃ catalystwere placed in a 1-liter stainless-steel batch pressure reactor equippedwith a stirrer and 1-liter hydrogen ballast tank. The Pd/Al₂O₃ catalystis commercially available from the Johnson-Mathey Corporation. Thereactor was sealed and subsequently purged with nitrogen and hydrogen toremove any air from the reactor. While stirring the reactor contents, 30parts by weight of anhydrous methylamine were added to the reactor. Thereactor was then pressurized with hydrogen to 5.86 MPa (850 psi), andheated to 120° C. Over a time period of 4 hours, 100 parts by weight ofthe intermediate product described above were added to the reactor.Substantially constant reactor conditions were maintained forapproximately 2 more hours after the addition of the intermediateproduct was complete, at which time the rate of hydrogen uptake from theballast tank fell below 0.0034 MPa/min (0.5 psi/min). The reactor wascooled to room temperature and depressurized, and the reaction productwas filtered to remove the catalyst. The solvent was then removed byrotary evaporation. The resulting reaction product wasmethylamine-terminated poly-(N-methylazetidine) with an estimated ANEWof about 117. It had an amine value of 877 mg KOH/g and the Brookfieldviscosity was determined to be 17 mPa·s using spindle S62 at 100 rpm.The M_(n) was determined to be approximately 239 using the GC techniquedescribed above. Methylamine-terminated poly-(N-methylazetidine) has thefollowing chemical structure:

The methylamine-terminated poly-(N-methylazetidine) compound of Example4 is designated as dimethyl secondary diamine 4, abbreviated DSD-4.DSD-4 was analyzed using GC and had the following polymer distributionby area percent, with “others” representing reaction by-products whichwere not separated or identified using GC, nor used in determiningM_(n):

n = 0 7.2% n = 1 17.6% n = 2 18.2% n = 3 15.8% n = 4 11.3% n = 5 7.9% n= 6 4.7% n = 7 2.5% Others 14.8%

Example 5 Synthesis of methylamine-terminated poly-(N-methylazetidine)

273.5 parts by weight of acrylonitrile and 5.5 parts of water wereplaced in a 1-liter stainless-steel batch pressure reactor equipped witha stirrer. The reactor was sealed and subsequently purged with nitrogento remove any air from the reactor. While stirring the reactor contents,100 parts by weight of methylamine were added to the reactor over a timeperiod of 4 hours. During the addition of the methylamine, the reactortemperature was maintained at approximately 55° C. This temperature wasthen maintained for 1.5 hours after the methylamine addition wascomplete. The reactor was cooled and the intermediate product removed.

35 parts by weight of isopropanol and 1.5 parts of Pd/Al₂O₃ catalystwere placed in a 1-liter stainless-steel batch pressure reactor equippedwith a stirrer and 1-liter hydrogen ballast tank. The Pd/Al₂O₃ catalystis commercially available from the Johnson-Mathey Corporation. Thereactor was sealed and subsequently purged with nitrogen and hydrogen toremove any air from the reactor. While stirring the reactor contents, 30parts by weight of anhydrous methylamine were added to the reactor. Thereactor was then pressurized with hydrogen to 5.86 MPa (850 psi), andheated to 120° C. Over a time period of 4 hours, 100 parts by weight ofthe intermediate product described above were added to the reactor.Substantially constant reactor conditions were maintained forapproximately 2 more hours after the addition of the intermediateproduct was complete, at which time the rate of hydrogen uptake from theballast tank fell below 0.0034 MPa/min (0.5 psi/min). The reactor wascooled to room temperature and depressurized, and the reaction productwas filtered to remove the catalyst. The solvent was then removed byrotary evaporation. The resulting reaction product wasmethylamine-terminated poly-(N-methylazetidine) with an estimated ANEWof about 113. It had an amine value of 837 mg KOH/g and the Brookfieldviscosity was determined to be 21 mPa·s using spindle S62 at 100 rpm.The M_(n) was determined to be approximately 273 using the GC techniquedescribed above. Methylamine-terminated poly-(N-methylazetidine) has thefollowing chemical structure:

The methylamine-terminated poly-(N-methylazetidine) compound of Example5 is designated as dimethyl secondary diamine 5, abbreviated DSD-5.DSD-5 was analyzed using GC and had the following polymer distributionby area percent, with “others” representing reaction by-products whichwere not separated or identified using GC, nor used in determiningM_(n):

n = 0 3.4% n = 1 11.0% n = 2 15.8% n = 3 17.0% n = 4 12.7% n = 5 10.7% n= 6 6.7% n = 7 0.9% Others 17.8%

Constructive Example 6 Constructive Synthesis of Methylamine-TerminatedPolyoxypropylene

The synthesis reaction can be carried out in a continuous reactor suchas a stainless steel tube of about 3.175 cm inside diameter and about 69cm in length. First, place about 487 mL of a pre-reduced, pelletizednickel-copper-chromium catalyst in the reactor. The catalyst can containapproximately 75 mole percent nickel, 23 mole percent copper and 2 molepercent chromium, as described in U.S. Pat. No. 3,654,370, which isincorporated herein by reference. To the reactor contents, add hydrogenat a rate of about 160 liters per hour (measured at 0° C. and 1atmosphere pressure), methylamine at a rate of about 686 g/hr, and anapproximate 50% solution of polypropylene glycol in cyclohexane at arate of about 304 g/hr. The molecular weight of the polypropylene glycolused in this synthesis can be around 400. The reactor temperature shouldbe controlled at around 240° C., and the pressure maintained atapproximately 3000 psig.

The reactor effluent is subsequently stripped of methylamine andcyclohexane by heating to approximately 150° C. The resulting reactionproduct is a liquid comprising methylamine-terminated polyoxypropylene.The reaction product should have in excess of about 90% of thetheoretical content of amino groups, and less than 10% of the originalhydroxyl groups. Typically, above about 90% of the amine groups aresecondary amino groups resulting in the desired product,methylamine-terminated polyoxypropylene, which is an N,N′-dimethylsecondary diamine polymer. The distribution of molecular sizes and theM_(n) can then be determined using the GC technique previouslydescribed. Additional, the ANEW can be estimated for themethylamine-terminated polyoxypropylene using analytical methods thatare well known to those skilled in the art.

Example 7 Synthesis Of a Mannich base derivative frommethylamine-terminated poly-(N-methylazetidine) andtris-(dimethylaminomethyl)phenol

50.03 g of the dimethyl secondary diamine of Example 3 (DSD-3) and 26.61g of K54, tris-(dimethylaminomethyl)phenol, were placed in around-bottom flask equipped with a nitrogen inlet, mechanical stirrer,thermocouple, and a reflux condenser. The top of the reflux condenserwas connected to a Dewar condenser which was attached to the center neckof a second round-bottom flask, which was equipped with a magnetic stirbar and a nitrogen outlet. This second round-bottom flask was chargedwith 19.87 g of acetic acid and 39.77 g of distilled water.

While stirring, the temperature of the mixture of DSD-3 and K54 wasincreased from ambient temperature to 190° C. over the course of 2.5hours, and held at this temperature for an additional 3 hours.Subsequently, the temperature was increased to 200° C. and maintainedfor 1 hour.

The resulting reaction product was a Mannich base derivative ofmethylamine-terminated poly-(N-methylazetidine). This composition had aviscosity of 639 mPa·s at 25° C. using Brookfield CP52 spindle at 20rpm, and an amine value of 831 mg KOH/g. In the tables that follow, thiscomposition of Example 7 is designated as MBC-7.

Example 8 Synthesis of a Mannich base derivative frommethylamine-terminated poly-(N-methylazetidine) andtris-(dimethylaminomethyl)phenol

50.02 g of the dimethyl secondary diamine of Example 4 (DSD-4) and 20.45g of K54 were placed in a round-bottom flask equipped with a nitrogeninlet, mechanical stirrer, thermocouple, and a reflux condenser. The topof the reflux condenser was connected to a Dewar condenser which wasattached to the center neck of a second round-bottom flask, which wasequipped with a magnetic stir bar and a nitrogen outlet. This secondround-bottom flask was charged with 15.29 g of acetic acid and 30.56 gof distilled water.

While stirring, the temperature of the mixture of DSD-4 and K54 wasincreased from ambient temperature to 160° C. over the course of 20minutes, and held at this temperature for an additional 3 hours.Subsequently, the temperature was increased to 180° C. for 2 hours, thenincreased to 200° C. for additional 2 hours.

The resulting reaction product was a Mannich base derivative ofmethylamine-terminated poly-(N-methylazetidine). This composition had aviscosity of 2614 mPa·s at 25° C. using Brookfield CP52 spindle at 20rpm, and an amine value of 820 mg KOH/g. In the tables that follow, thiscomposition of Example 8 is designated as MBC-8.

Example 9 Synthesis of a Mannich base derivative frommethylamine-terminated poly-(N-methylazetidine) andtris-(dimethylaminomethyl)phenol

50.05 g of the dimethyl secondary diamine of Example 4 (DSD-4) and 17.72g of K54 were placed in a round-bottom flask equipped with a nitrogeninlet, mechanical stirrer, thermocouple, and a reflux condenser. The topof the reflux condenser was connected to a Dewar condenser which wasattached to the center neck of a second round-bottom flask, which wasequipped with a magnetic stir bar and a nitrogen outlet. This secondround-bottom flask was charged with 13.27 g of acetic acid and 26.5 g ofdistilled water.

While stirring, the temperature of the mixture of DSD-4 and K54 wasincreased from ambient temperature to 200° C. over the course of 3hours, and maintained at this temperature for an additional 3 hours.

The resulting reaction product was a Mannich base derivative ofmethylamine-terminated poly-(N-methylazetidine). This composition had aviscosity of 59 m Pa-s at 25° C. using Brookfield CP52 spindle at 20rpm, and an amine value of 850 mg KOH/g. In the tables that follow, thiscomposition of Example 9 is designated as MBC-9.

Example 10 Synthesis of a Mannich base derivative frommethylamine-terminated poly-(N-methylazetidine) andtris-(dimethylaminomethyl)phenol

46.75 g of the dimethyl secondary diamine of Example 4 (DSD-4) and 12.74g of K54 were placed in a round-bottom flask equipped with a nitrogeninlet, mechanical stirrer, thermocouple, and a reflux condenser. The topof the reflux condenser was connected to a Dewar condenser which wasattached to the center neck of a second round-bottom flask, which wasequipped with a magnetic stir bar and a nitrogen outlet. This secondround-bottom flask was charged with 9.54 g of acetic acid and 19.04 g ofdistilled water.

While stirring, the temperature of the mixture of DSD-4 and K54 wasincreased from ambient temperature to 160° C. over the course of 20minutes, and held at this temperature for an additional 1 hour.Subsequently, the temperature was increased to 178° C. and maintainedfor 30 minutes, then increased to 187° C. and maintained for 1 hour, andthen increased to 195° C. and maintained for 2 hours.

The residual methylamine-terminated poly-(N-methylazetidine) reactant inthe system was estimated by GC, using diglyme as an internal standard,and measuring the amount of the n=1 and n=2 oligomers before and aftercompletion of the reaction. The average of the two measurementsindicated that the final product incorporated approximately 44% of theweight of the methylamine-terminated poly-(N-methylazetidine) reactantbased on the weight of DSD-4 charged in the initial reaction mixture.

Comparative Examples 11-12 Coatings Made from Comparative Epoxy-HardenerCompositions

Formulations and the resulting properties of comparative examples 11-12are illustrated in Tables 2-3. As indicated in the tables, the coatingsbased on the phenalkamines of Examples 11-12 had slow dry speeds at 5°C., particularly as measured by the thumb twist method. Additionally,the coatings of Examples 11-12 exhibited poor hardness development,waterspot resistance, reverse impact and mandrel bend flexibility.

TABLE 2 Comparative examples cured at 25° C. or following cure schedulesA-C. Example 11 12 Comparative Hardener NC541LV CX-105 Use Level (PHR)67 76 Mix Viscosity (mPa · s) 6,250 22,000 Coating Solids (weight %) Atmix viscosity 100 100 Diluted to 1 Pa · s^(a) 94 87 Thin Film Set Time(hr) Phase 2/Phase 3 4.6/5.8 —/— Coating Appearance Specular Gloss20°/60° 82/92 10/50 Visual glossy semi gloss Persoz Hardness (s) Day1/Day 7 165/275  90/190 Impact Resistance (kg · cm) Direct/ReverseSchedule A 125/20  85/17 Schedule B 115/45  Schedule C Mandrel Bend (%elongat.) Schedule A 5.2 5.3 Conical Bend (% elongat.) Schedule A <2 <2^(a)adjusted with xylene:butanol (3:1) to match comparable applicationviscosity

TABLE 3 Comparative examples cured at 5° C. Example 11 12 Thin Film SetTime (hr) Phase 2/Phase 3 14/20  9.7/15.2 Coating Appearance SpecularGloss 20°/60° 40/80 12/34 Visual greasy Matte Persoz Hardness (s) Day2/Day 7  —/115 25/75 Thumb Twist method Set-to-Touch Time (hr) 22   24Dry-to-Handle Time (hr) 26 >28 Waterspot Resistance Day 1/Day 7 (1-5, 5= best) 1/3 2/3

Examples 13-17 Coatings Made from Amine-Epoxy Compositions

Formulations and the resulting properties of inventive examples 13-17are shown in Tables 4-5. Examples 13-17 illustrate the propertiesobtained from exemplary formulations and coatings utilizing compositionscontaining Mannich base derivatives of N,N′-dimethyl secondary diaminesin accordance with the present invention.

As indicated in Table 4, Examples 13, 14, and 16, utilized MBC-7, MBC-8,and MBC-9, respectively, with a multifunctional amine, MPCA. Example 15did not contain benzyl alcohol. Example 17 contained MBC-9 and aderivative of a multifunctional amine (phenalkamine).

As illustrated by Tables 2 and 4, the coatings of Examples 13-17exhibited higher gloss, and superior flexibility and impact resistance,as compared to Examples 11-12. The data in Tables 3 and 5 at 5° C.demonstrate the generally improved gloss and faster dry speed of thecoatings of Examples 13-17 versus those of Examples 11-12. Tables 2-5also show the significantly increased Persoz hardness for the coatingsof Examples 13-17 over the comparable coatings of Examples 11-12.Example 15 additionally demonstrates that Mannich base derivatives ofthe present invention can be used as sole curatives to yield 100% solidsformulations with generally good coating properties.

TABLE 4 Examples 13-17 cured at 25° C. or following cure schedules A-C.Example 13 14 15 16 17 Hardener Composition MBC-7 75 MBC-8 75 MBC-9 100MBC-9 75 MBC-9 50 (Parts by Weight) MPCA 25 MPCA 25 MPCA 25 CX-105 50 BA42 BA 36 BA 42 Use Level (PHR) with 84 91 94 86 83 DGEBA Mix Viscosity(mPa · s) 2,700 4,800 4,000 1,900 8,800 Coating Solids (weight %) 86 87100 86 100 Thin Film Set Time (hr) Phase 2/Phase 3 2.4/3.1 1.8/2.8 —/——/— —/— Coating Appearance Specular Gloss 20°/60° 100/101 99/101 >95 >95 >95 Visual high gloss high gloss high gloss high glosshigh gloss Persoz Hardness (s) Day 1/Day 7 315/325 305/320 305/280280/285 315/325 Impact Resistance (kg · cm) Direct/Reverse Schedule A120/40  185/35  200/200 170/85  140/35  Schedule B 200/175 200/200Schedule C 165/30  150/20  Mandrel Bend (% elongat.) Schedule A 33 — 3333 5.3 Conical Bend (% elongat.) Schedule A >33 — >33 >33 4.4^(a)adjusted with xylene:butanol (3:1) to match comparable applicationviscosity

TABLE 5 Examples 13-17 cured at 5° C. Example 13 14 15 16 17 Thin FilmSet Time (hr) Phase 2/Phase 3  7.4/10.0  6.6/11.0 7.0/—  6.5/9.09.0/12.6 Thumb Twist method Set-to-Touch Time (hr) — — — 8  9Dry-to-Handle Time (hr) <16 <16 <22 9 10 Coating Appearance SpecularGloss 20°/60° 29/53 58/84 40/73  97/100 81/94 Visual semi-glosssemi-gloss semi-gloss high gloss glossy Waterspot Resistance Day 1/Day 7(1-5, 5 = best) 5/5 —/— 2/3 5/5 4/5 Persoz Hardness (s) Day 1/Day 7 95/240  80/215 45/85  75/180 135/250

Examples 18-25 Synthesis of Mannich base derivatives frommethylamine-terminated poly-(N-methylazetidine), phenol, andformaldehyde

Phenol and the dimethyl secondary diamine of Example 4 (DSD-4) wereplaced in a 4-necked reaction flask equipped with a nitrogen purge,mechanical stirrer, thermocouples, and reflux condenser, at thequantities and conditions listed in Table 6. Reaction temperature andthe head temperature at the take-off point of the condenser weremonitored using the thermocouples.

The general procedure for each of Examples 18-25 was as follows. Aformaldehyde solution (37% in water and methanol) was added slowly atroom temperature over a 20-30 minute period to the reaction flask,keeping the exothermic reaction to a minimum. Once addition of theformaldehyde was complete, a sample was taken for GC analysis of freephenol as an indicator of the progress of the reaction. The temperaturewas then increased to the desired temperature (70 or 90° C.) and held atthat temperature for about 6 hours as methanol and water were removedfrom the reaction mixture. The reaction mixture was sampled hourly forfree phenol by GC. Total reaction times were generally about 6.5 to 7hours.

Methanol and water were then removed by distillation, accomplished byheating the reaction product to 115° C. and allowing the distillate totravel through a 28 mm distillation column (available from Ace Glasscatalog #6566-03) into a condenser cooled to 12° C. Once the headtemperature started to drop after the distillate had been collected, thepot temperature was increased in 10° C. increments and the distillationstep repeated. Generally, three distillation cuts were necessary tostrip the final reaction product of water to less than 1-2% water.

Table 7 summarizes the characterization of the final reaction productsof Examples 18-25. The free phenol in all products was less than 2%, andin most cases, the free phenol was less than 0.5%. Hence, Mannich basederivatives of a N,N′-dimethyl secondary amine polymer with very lowlevels of residual phenol can be prepared by the direct reaction ofphenol, formaldehyde, and a N,N′-dimethyl secondary amine polymer, suchas methylamine-terminated poly-(N-methylazetidine).

TABLE 6 Experimental Conditions for Examples 18-25. CH₂O/ DSD-4/ PhenolPhenol 37% Reaction Mole Mole DSD- Phenol CH₂O Temp. Example Ratio Ratio4 (g) (g) (g) (° C.) 18 2.6 3.5 225.07 25.96 58.19 70 19 2.9 3.5 225.0825.98 64.99 70 20 2.6 4.5 233.26 20.88 46.91 70 21 2.9 4.5 233.21 20.9452.13 70 22 2.6 3.5 225.33 26.23 58.95 90 23 2.9 3.5 225.24 26.56 64.8790 24 2.6 4.5 231.26 20.86 47.20 90 25 2.9 4.5 233.33 20.99 52.36 90

TABLE 7 Characterization of Mannich base derivatives of Examples 18-25.Viscosity Final Yield Calculated % Water (mPa · s, Example (g) AHEW(K.F.) % Phenol 25° C.) 18 226.75 188 1.7 0.37 309 19 216.88 193 2.00.09 704 20 217.14 153 1.5 1.54 94 21 218.24 162 1.0 0.72 132 22 212.56177 1.4 0.06 688 23 200.00 178 1.4 0.07 724 24 225.94 162 0.5 0.15 10625 225.81 167 1.3 0.06 157 Note % Water (K.F.) indicates measurement byKarl Fischer titration

Example 26 Synthesis of a Mannich base derivative frommethylamine-terminated poly-(N-methylazetidine) andtris-(dimethylaminomethyl)phenol

2585.1 g of the dimethyl secondary diamine of Example 4 (DSD-4) and918.9 g of K54 were placed in a round-bottom flask equipped with anitrogen inlet, mechanical stirrer, thermocouple, and a refluxcondenser. The top of the reflux condenser was connected to a Dewarcondenser which was attached to the center neck of a second round-bottomflask, which was equipped with a magnetic stir bar and a nitrogenoutlet. This second round-bottom flask was charged with 684.4 g ofacetic acid and 1368.6 g of distilled water.

While stirring, the temperature of the mixture of DSD-4 and K54 wasincreased from ambient temperature to 150° C. over the course of 114minutes, and held at this temperature for an additional 7.75 hours.

The resulting reaction product was a Mannich base derivative ofmethylamine-terminated poly-(N-methylazetidine). This composition had aviscosity of 2945 mPa·s at 25° C. using Brookfield CP52 spindle at 20rpm, and an amine value of 762 mg KOH/g. The calculated AHEW for thiscomposition was 249.

Examples 27-35 Coatings Made from Amine-Epoxy Compositions

Formulations and the resulting properties of Examples 27-35 aresummarized in Table 8. In accordance with the present invention,Examples 27-35 illustrate the properties obtained from exemplaryformulations and coatings utilizing compositions containing Mannich basederivatives of N,N′-dimethyl secondary diamines and a multifunctionalamine.

Hardeners for these experiments were prepared by mixing 50 parts byweight of the Mannich base derivatives of Examples 18-26 with 50 partsby weight of CX-105. The resulting amine curing agent compositions werethen contacted and mixed with the epoxy resin, and coated and tested asdescribed above. For Examples 27-34, the stoichiometric ratio of epoxygroups in the epoxy resin to amine hydrogens in the amine curing agentcomposition (hardener composition) was about 1:1. The AHEW of therespective Mannich base derivative of Examples 18-26 provided above wasused in this determination. The AHEW in Table 8 is that of the aminecuring agent composition or hardener composition, i.e., CX-105 mixedwith the respective Mannich base derivative. The epoxy:aminestoichiometric ratio for Example 35 was about 1.18:1.

As compared to the coatings of Examples 11-12 cured at 5° C. (see Table3), the coatings of Examples 27-35 generally show an improvement indrying time (phase 2 thin film set time) and 20° gloss. In addition, 7day Persoz hardness is increased dramatically for Examples 27-28, 31-32,and 35.

TABLE 8 Examples 27-35 cured at 5° C. and 60% RH. Example 27 28 29 30 3132 33 34 35 Hardener 18 19 20 21 22 23 24 25 26 Example AHEW 165 168 147151 159 159 151 154 156 Persoz Day 1 40 45 30 30 25 30 30 25 130Hardness Day 3 150 145 75 60 80 130 65 55 220 Day 7 235 190 105 80 215210 75 100 250 Gloss 20° 35 40 30 30 75 45 60 35 75 Thin Film Set [I]3.7 4.0 3.8 4.1 4.3 3.3 3.5 3.5 3.5 Time (hr) [II] 9.0 9.9 9.8 9.6 9.28.5 8.7 8.7 7.7

Examples 36-41 Impact of the Stoichiometric Ratio of Epoxy Groups toAmine Hydrogens on Coating Properties

Formulations and the resulting properties of inventive Examples 36-41are summarized in Table 9. In accordance with the present invention,Examples 36-41 illustrate the effect of changing the stoichiometricratio of epoxy groups in the epoxy component to amine hydrogens in theamine component. The amine component was prepared by mixing 75 parts byweight of Example 26 (Mannich base derivative of methylamine-terminatedpoly-(N-methylazetidine) having an ANEW of about 249), 25 parts MPCAhaving an ANEW of about 57, and 44 parts benzyl alcohol. The resultingamine curing agent compositions were then contacted and mixed with theepoxy resin at the stoichiometric ratio indicated, and coated and testedas described above.

Examples 36-41 demonstrate that improved hardness and gloss result whenexcess epoxy is employed. In this set of examples, optimum propertieswere obtained with a stoichiometric ratio of epoxy to amine of about1.16:1 in Example 40.

TABLE 9 Examples 36-41 cured at 5° C. and 60% RH. Example 36 37 38 39 4041 Stoichiometry 1:1.04 1:1 1.04:1 1.09:1 1.16:1 1.25:1 Epoxy:AmineGroups AHEW of blend 198 191 183 174 163 151 Use Level (PHR) 104 100 9692 86 80 Persoz Hardness 75 95 110 135 150 130 Day 2 Gloss - 20° 55 6580 85 95 80 Gloss - 60° 85 90 95 105 110 95 Thin Film Set 4.7 4.7 4.84.8 4.8 4.8 Time (hr) Phase 2

1. A composition comprising a Mannich base reaction product of: (a) atleast one aldehyde compound; (b) at least one phenol compound; and (c)at least one N,N′-dimethyl secondary diamine polymer having anumber-average molecular weight (M_(n)) from about 140 to about
 1000. 2.The composition of claim 1, wherein: the at least one aldehyde compoundcomprises formaldehyde; the at least one phenol compound comprisesphenol, cresol, t-butyl phenol, nonyl phenol, cardanol, or a combinationthereof; and the at least one N,N′-dimethyl secondary diamine polymercomprises methylamine-terminated poly-(N-methyl-azetidine),methylamine-terminated poly-(N-methyl-azacycloheptane), or a combinationthereof.
 3. An amine curing agent composition comprising: (i) thecomposition of claim 1; and (ii) at least one multifunctional aminehaving 3 or more active amine hydrogens.
 4. An amine-epoxy compositioncomprising: (a) the amine curing agent composition of claim 3; and (b)an epoxy component comprising at least one multifunctional epoxy resin.5. A method comprising curing the amine-epoxy composition of claim
 4. 6.A composition obtained by the method of claim
 5. 7. An article ofmanufacture comprising the composition of claim
 6. 8. The article ofclaim 7, wherein the article is a coating, an adhesive, a constructionproduct, a flooring product, or a composite product.
 9. A compositioncomprising a reaction product of: (a) at least one di-substituted ortri-substituted Mannich base compound; and (b) at least oneN,N′-dimethyl secondary diamine polymer having a number-averagemolecular weight (M_(n)) from about 140 to about
 1000. 10. Thecomposition of claim 9, wherein: the at least one di-substituted ortri-substituted Mannich base compound comprisesbis-(dimethylaminomethyl)phenol, tris-(dimethylaminomethyl)phenol, or acombination thereof; and the at least one N,N′-dimethyl secondarydiamine polymer comprises methylamine-terminatedpoly-(N-methyl-azetidine), methylamine-terminatedpoly-(N-methyl-azacycloheptane), or a combination thereof.
 11. An aminecuring agent composition comprising: (i) the composition of claim 9; and(ii) at least one multifunctional amine having 3 or more active aminehydrogens.
 12. An amine-epoxy composition comprising: (a) the aminecuring agent composition of claim 11; and (b) an epoxy componentcomprising at least one multifunctional epoxy resin.
 13. A methodcomprising curing the amine-epoxy composition of claim
 12. 14. Acomposition obtained by the method of claim
 13. 15. An article ofmanufacture comprising the composition of claim
 14. 16. The article ofclaim 15, wherein the article is a coating, an adhesive, a constructionproduct, a flooring product, or a composite product.
 17. The compositionof claim 1 comprising compounds having the formula:

wherein: m is 1, 2, or 3; R is a hydrogen atom or a C₁-C₁₈ linear orbranched alkyl or alkenyl group; each R′ independently is a hydrogenatom or a moiety having the formula:

wherein: R is defined as above; t is 0, 1, or 2; each R″ independentlyis a hydrogen atom or a moiety having the formula;

wherein: R is defined as above; u is 0, 1, or 2; and each Xindependently is a polyoxyalkylene moiety or a moiety having theformula:

wherein: R₁ is a C₂-C₈ linear or branched alkanediyl; and n is aninteger in a range from 1 to 10, inclusive.
 18. The composition of claim17, wherein R is a hydrogen atom, a methyl group, an ethyl group, apropyl group, a butyl group, a tert-butyl group, an octyl group, a nonylgroup, a dodecyl group, a C₁₅ alkyl group, or a C₁₅ alkenyl group. 19.The composition of claim 17, wherein each R′ is a hydrogen atom.
 20. Thecomposition of claim 17, wherein X is moiety having the formula:

and wherein R₁ is a C₃-C₆ linear or branched alkanediyl. 21-25.(canceled)
 26. An amine curing agent composition comprising: (i) thecomposition of claim 17; and (ii) at least one multifunctional aminehaving 3 or more active amine hydrogens.